Factory Workshop Manual
Make
Dodge
Model
Grand Caravan Fwd
Engine and year
V6-201 3.3L VIN R MFI (1998)
Please navigate through the PDF using the options
provided by OnlyManuals.com on the sidebar.
This manual was submitted by
Anonymous
Date
1st January 2018
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations > Page 7
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations > Page 8
Keyless Entry Module: Adjustments
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30
seconds or when ignition switch is turned OFF, the
RKE module will end the programming mode. A single chime will sound to verify that the RKE
module will no longer receive additional Vehicle Access Code(s).
7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each
key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Accessories and Optional Equipment > Keyless
Entry Module > Component Information > Locations > Page 9
Keyless Entry Module: Service and Repair
REMOVAL
1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel.
RKE Module
3. Disconnect wire connector from RKE module. 4. Remove the RKE module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 14
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 15
Keyless Entry Module: Adjustments
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30
seconds or when ignition switch is turned OFF, the
RKE module will end the programming mode. A single chime will sound to verify that the RKE
module will no longer receive additional Vehicle Access Code(s).
7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each
key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 16
Keyless Entry Module: Service and Repair
REMOVAL
1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel.
RKE Module
3. Disconnect wire connector from RKE module. 4. Remove the RKE module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range
Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT: Memory Power Seat Travel Range
MODELS:
1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand
Cherokee 1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and
remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in
MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the
motor end, fails to change. The feedback voltage potentiometers vary the position sensing
feedback voltage based on seat position/movement (no movement, no change in position sensing
feedback voltage). The seat motor automatically stops at the soft stop on any subsequent
movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when
something is stuck under or behind the seat that causes the seat to stop moving). These soft stops
can prevent the seat from being able to have memory positions set over the full range of travel.
Also, positions that were previously programmed to locations beyond an updated soft stop limit will
not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed
into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure
to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat
operation.
There are two potential reasons for intermittent memory functioning of the seats. The first
possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned
by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in
the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can
be caused by a poor connection at pin 23 of the P34 connector which is located near the right side
of the steering column. This circuit is used to communicate and control the seat module. This circuit
"locks out" movement when the vehicle is not in park and also causes seat position recall when
used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for
fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat
to move the seat in one direction to the end of travel, then energize the seat again in the same
direction until it stops and for three additional seconds after it stops. The amount that the seat
moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat
this procedure for each of the directions of movement (one at a time).
NOTE:
IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF
SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM
(AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE
MANUAL).
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation
Seat Heater Control Module: Description and Operation
SYSTEM OPERATION
The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate
the electric seat heater elements. Two modules are used in the vehicle, one for each front seat.
The HSCM for each seat is installed on front portion of each cushion pan. The wire harness
connector is secured by an integral clip to the inside surface of the outboard seat cushion frame.
Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat
cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery
feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 27
Seat Heater Control Module: Testing and Inspection
Before testing the heated seat control module, test the heated seat switch, the heated seat
elements, and the heated seat sensor as described. If testing of the heated seat switch, elements,
and sensor reveals no problems, proceed as follows.
1. Replace the heated seat control module with a known good unit and test the operation of the
heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.
2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat
sensor to the heated seat control module. Repair any
short or open circuits as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 28
Seat Heater Control Module: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the
vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the
module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5.
Remove module from seat cushion pan.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > ABS Main Relay >
Component Information > Description and Operation
ABS Main Relay: Description and Operation
ABS FUSES
Fuse Locations In Power Distribution Center
The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center
(PDC). The PDC is located on the drivers side of the engine compartment forward of the strut
tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the
junction block.
On vehicles equipped with traction control, the fuse for the traction control switch is also located in
the junction block.
The junction block is located on the left hand front cowl panel on the vehicle.
ABS RELAYS
On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are
located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will
need to be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
To HCU Mounting Bolts .......................................................................................................................
.................................................. 2 Nm (17 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 36
Controller Antilock Brakes Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 37
Controller Antilock Brakes Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Specifications > Page 38
Electronic Brake Control Module: Description and Operation
The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds
and controls the antilock functions. The CAB contains two microprocessors that receive identical
sensor signals and then independently process the information. The results are then compared to
make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock
Brake System (ABS) amber warning lamp.
The primary functions of the CAB are to:
- detect wheel locking tendencies
- control fluid pressure modulation to the brakes during antilock stop
- monitor the system for proper operation
- provide communication to the DRB while in diagnostic mode
- store diagnostic information in non-volatile memory
The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is
detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its
hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system
with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic
circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor
during an antilock stop.
The antilock brake system is constantly monitored by the CAB for proper operation If the CAB
detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp.
If the antilock function is disabled, the system will revert to standard base brake system operation.
CAB Inputs Include The Following:
- ABS Warning Lamp
- Diagnostic Communication
- Four Wheel Speed Sensors
- Ignition Switch
- Fused B+
- Stop Lamp Switch
- Traction Control Switch
CAB Outputs Include The Following:
- ABS Warning Light Actuation
- Voltage
- Eight Valves
- Ten Valves With Traction Control
- Diagnostic Communication
- Body Controller Communication
- Traction Control Lamp Illumination
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Service and Repair > Removal
Electronic Brake Control Module: Service and Repair Removal
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control
Unit (HCU).
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
CAB 25 Way Connector
Unlocking CAB 25 Way Connector
4. Remove the 25 way connector from the Controller Antilock Brake (CAB) located on the bottom of
the HCU. The 25 way connector is removed
from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as
far out as possible. This will unlock and raise the 25 way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake
tubes.
5. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 41
Brake Tube Connections To HCU
6. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
HCU To Suspension Cradle Mounting Bolts
7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.
8. Remove HCU and the mounting bracket as a unit from the vehicle.
HCU Mounting Bolts
9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the
mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 42
Pump Motor To CAB Wiring Harness
10. Unplug the pump motor wiring harness from the CAB.
CAB Attaching Bolts
11. Remove the 4 bolts attaching the CAB to the valve block of the HCU.
Remove/Install CAB
12. Remove the CAB from the valve block of the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 43
Electronic Brake Control Module: Service and Repair Installation
Remove/Install CAB
1. Install the Controller Antilock Brake (CAB) on the valve block of the Hydraulic Control Unit
(HCU).
CAB Attaching Bolts
2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting
bolts to a torque of 2 Nm (17 inch lbs.).
Pump Motor To CAB Wiring Harness
3. Plug the pump/motor wiring harness into the CAB.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 44
HCU Mounting Bolts
4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting
bracket. Tighten the 3 mounting bolts to a torque
of 11 Nm (97 inch lbs.).
CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front
suspension crossmember.
HCU To Suspension Cradle Mounting Bolts
5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning valve, the brake tubes must be held in proper
orientation when tightened and torqued. These tubes must not contact each other or other vehicle
components when installed.
Brake Tube Connections To HCU
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Brakes and Traction Control > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 45
CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located
correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
HCU mounting bracket.
6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
Unlocking CAB 25 Way Connector
7. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
Brake Tube Routing Clips
8. Install the routing clips on the brake tubes. 9. Lower vehicle.
10. Connect negative cable back on negative post of the battery. 11. Bleed the base brakes and
the ABS brakes hydraulic system. 12. Road test vehicle to ensure proper operation of the base and
ABS brake systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan
Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan
Relay and PCM > Page 55
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan
Relay and PCM > Page 56
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan
Relay and PCM > Page 57
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan
Relay and PCM > Page 58
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: Customer Interest PCM - Improper Cooling Fan Relay
Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM Improper Cooling Fan Relay Actuation > Page 64
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 70
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 71
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 72
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 73
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan
Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator Cooling Fan
Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 78
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan
Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 84
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 90
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 91
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 92
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling Fan Motor
Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 93
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 94
Radiator Cooling Fan Motor Relay: Locations
Cooling Fan Relay Location
Radiator Fan Relay Mounted On Left Front Frame Rail
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 95
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 96
Radiator Cooling Fan Motor Relay: Description and Operation
Fig 41 Fan Control Module
SOLID STATE FAN RELAY -- PCM OUTPUT
The radiator fan runs at a variable speed depending on coolant temperature and A/C system
pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR).
A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR.
Depending upon the amount of pulse ON time, the SSFR puts out a proportional voltage to the fan
motor at the lower speed. For instance, if the ON time is 30 percent, then the voltage to the fan
motor will be 3.6 volts.
when engine coolant temperature reaches approximately 102°C (215°F) the PCM grounds the
SSFR. If engine coolant reaches 107°C (225°F) the PCM grounds the high speed ground relay and
high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay
and high speed ground relay when coolant temperature drops to approximately 101°C (214°F).
When coolant temperature drops to 101°C (214°F) the fan operates at low speed. The PCM
de-energizes the low speed relay when coolant temperature drops to approximately 93°C (199°F).
Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air
conditioning switch closes at 285 psi ±10 psi. When air conditioning pressure drops approximately
40 psi, the pressure switch opens and the fan operates at low speed.
The SSFR is located on the left front inner frame -- just behind the radiator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Cooling System > Radiator Cooling Fan Motor
Relay > Component Information > Technical Service Bulletins > Page 97
Radiator Cooling Fan Motor Relay: Testing and Inspection
Fan control is accomplished two ways. A pressure transducer on the compressor discharge line
sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to
this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant
temperature sensor which sends the message to the PCM. The fan will not run during cranking
until the engine starts no matter what the coolant temperature is.
CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support.
The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is
properly attached to prevent the following:
- Intermittent engine overheating.
- Relay "thermal" shutdown, or relay damage.
For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code
Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Front Blower Motor Relay
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Locations > Front Blower Motor Relay > Page 103
Blower Motor Relay: Locations Rear Blower Relay
Rear Blower Motor Relay
This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Description and Operation > Front Blower Motor Relay
Blower Motor Relay: Description and Operation Front Blower Motor Relay
Circuit Operation
Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the
HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1.
The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power
Distribution Center (PDC).
The coil side of the relay is energized when the ignition switch is in the RUN position only. Power
for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the
relay
Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit
A22.
Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl
panel.
Ground for the blower motor is controlled through the blower motor resistor and the blower motor
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Blower Motor Relay > Component
Information > Description and Operation > Front Blower Motor Relay > Page 106
Blower Motor Relay: Description and Operation Rear Blower Relay
Circuit Operation
Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp
fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear
blower motor passes through the temperature sensor and one or more resistors, depending on
speed selection.
Two switches operate the rear blower motor by supplying ground; the front control switch and the
rear control switch. The front control switch must be in the ON position for the rear control switch to
operate the rear blower motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Component Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - HVAC > Compressor Clutch Relay > Component
Information > Locations > Component Locations > Page 111
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Instrument Panel > Cigarette Lighter Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Fog/Driving Lamp Relay: Locations
Instrument Panel Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 120
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions
Fog/Driving Lamp Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 123
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 124
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 125
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 126
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 127
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 128
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 129
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 130
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 131
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 132
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 133
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 134
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 135
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 136
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 137
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 138
Fog/Driving Lamp Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 139
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 140
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 141
Fog/Driving Lamp Relay: Electrical Diagrams
Front Lighting (Part 2 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 142
Front Lighting (Part 3 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 143
Front Lighting (Part 6 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module
> Component Information > Description and Operation
Headlamp Control Module: Description and Operation
GENERAL INFORMATION
Minor amounts of fogging may occur around the edges of the headlamp lens when exposed to
humid conditions. This is considered normal. The fogging will dissipate with increased ambient
temperature or headlamp usage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Control Module
> Component Information > Description and Operation > Page 147
Headlamp Control Module: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. From inside engine compartment, remove nuts holding
headlamp module to radiator closure panel. 3. Remove screw holding top of module to closure
panel.
Headlamp Module
4. Separate headlamp module from radiator closure panel. 5. Disengage wire connectors from
back of headlamp module. 6. Separate headlamp module from vehicle.
INSTALLATION
1. Place headlamp module in position on vehicle. 2. Engage wire connectors into back of headlamp
module. 3. Place headlamp module in position on radiator closure panel. 4. Install nuts to hold
headlamp module to radiator closure panel. 5. Install screw to hold top of module to closure panel.
6. Verify headlamp operation and alignment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 154
Horn Relay: Testing and Inspection
1. Remove horn relay.
Horn Relay
2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance.
If resistance not OK, replace relay. 3. Test for continuity between ground and terminal 85 of horn
relay.
a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground
when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as
necessary.
4. Using voltmeter, test voltage at:
a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM.
c. If incorrect voltage repair as necessary.
5. Insert a jumper wire between terminal 30 and 87 of the power distribution center.
a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn
Test.
Horns Will Not Sound Check horn fuse 6 in the Power Distribution Center and fuse 7 in the
Junction Block. If fuse is blown refer to FUSE BLOWN. If fuse is OK, refer to FUSE OK.
Fuse Blown 1. Verify condition of battery terminals and voltage. If battery connections and battery
charge is OK proceed to Step 2. 2. Using a voltmeter, test for battery voltage at both sides of horn
fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is
OK, on one side of fuse, the fuse is blown, proceed to Step 3.
3. Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If
amperage draw is greater than 20 amps without the
horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to
Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded
circuit exists between the horn relay and the horn. Proceed to step Step 5.
4. Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn
switch or circuit is shorted. If the amperage
draw does not drop to 0 amps, repair short at the Junction Block.
5. Disengage a wire connector from one of the horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does
not drop with both horns disconnected and the horn switch depressed, proceed to Step 6.
6. Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn
relay to ground. If continuity is detected, the
circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness.
Fuse OK 1. Remove the horn relay from the Junction Block. 2. Using a continuity tester, Depress
horn switch and test continuity from the X3 cavity of the horn relay to ground.
a. If continuity is detected, proceed to Step 3. b. If NO continuity, proceed to Step 4.
3. Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay
in the Junction Block.
a. If the horn sounds, replace the horn relay. b. If the horn does not sound, proceed to Step 4.
4. Remove airbag"horn pad from steering wheel. 5. Test continuity across horn switch connectors
with horn switch depressed.
a. If continuity is detected, repair open circuit between the relay and the horn switch. b. If NO
continuity, replace airbag cover.
6. Install horn relay into Junction Block. 7. Disengage wire connectors from horns.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 155
Horn And Connector
8. Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals
of the wire harness.
a. If voltage is detected, replace horns. b. If NO voltage, proceed to step Step 9.
9. With the horn switch depressed, test for voltage between the X2 circuit and ground.
a. If voltage OK, repair system ground at right cowl area. b. If NO voltage, repair open X2 circuit
between the relay and the horns.
Horns Sound Continuously
CAUTION: Continuous sounding of horns may cause relay to fail.
The horn switch (membrane) sometimes can be the cause without the switch being depressing. 1.
Remove the horn relay from the junction block. 2. Using a continuity tester, test continuity from the
X3 cavity of the horn relay to ground.
a. If continuity is detected, proceed to step Step 3. b. If NO continuity, replace the horn relay.
3. Remove the airbag/horn pad from the steering wheel and disengage horn connector. 4. Install
horn relay into junction block.
a. If horn does not sound, replace airbag cover/ horn pad. b. If horn sounds, repair grounded X3
circuit from junction block to clockspring in steering in steering column.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Power
Distribution Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Locations
Relay Box: Locations
ABS Fuses
ABS Fuses
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block
Relay Box: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 168
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 169
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 170
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 171
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 172
Relay Box: Diagrams Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 173
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 174
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 175
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 176
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Power and Ground Distribution > Relay Box >
Component Information > Diagrams > Junction Block > Page 177
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM Auto Lamp DTC Diagnostics
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations
Body Control Module: Component Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations >
Page 186
Body Control Module Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 189
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 190
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 191
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 192
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 193
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 194
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 195
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 196
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 197
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 198
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 199
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 200
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 201
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 202
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 203
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 204
Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 205
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 206
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 207
Body Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 208
Body Control Module: Electrical Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 209
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 210
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 211
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 212
Exterior Lighting (Park Lamps)
Information Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 213
Instrument Cluster
Interior Lighting
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 214
Power Door Locks W/Remote Keyless Entry (RKE)
Power Door Locks W/O Remote Keyless Entry (RKE)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 215
Radio (CCD) Without Infinity Sound
Radio (CCD) With Infinity Sound
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 216
Vehicle Communications
Vehicle Theft Security System (VTSS)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 217
Windshield Wiper (Front)
Windshield Wiper (Rear)
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 218
Body Control Module (Part 1 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 219
Body Control Module (Part 2 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 220
Body Control Module (Part 3 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 221
Body Control Module (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 222
Body Control Module (Part 5 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 223
Body Control Module (Part 6 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 224
Body Control Module (Part 7 Of 7)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician
Safety Information
Body Control Module: Technician Safety Information
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following approved procedures is very important to the safety of individuals performing
diagnostic tests.
DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and
can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED
or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive
wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician
Safety Information > Page 227
Body Control Module: Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will
severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with
rubbing alcohol.
Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the
test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear
view mirror or operate it yourself. Have an assistant available to operate the DRB.
Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes
or error messages may occur.
Servicing Sub-Assemblies
Some components of the body system are intended to be serviced in assembly only. Attempting to
remove or repair certain system sub-components may result in personal injury and/or improper
system operation. Only those components with approved repair and installation procedures in the
service manual should be serviced.
DRBIII Safety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious
or possibly fatal injury. Carefully read and understand the cautions and the specification limits.
^ Follow the vehicle manufacturer's service specifications at all times.
^ Do not use the DRB if it has been damaged.
^ Do not use the test leads if the insulation is damaged or if metal is exposed.
^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
^ Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
^ Do not exceed the limits shown in the table below:
FUNCTION/INPUT LIMIT
Volts 0 - 500 peak volts AC 0 - 500 volts DC
Ohms (resistance)* 0-1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated 0 - 10 kHz
Temperature -58 - 11000 F -50 - 600 C
* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered
circuit.
^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
^ Use caution when measuring voltage above 25v DC or 25v AC.
^ The circuit being tested must be protected by a 1OA fuse or circuit breaker.
^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure
circuits exceeding 10A.
^ When testing for the presence of voltage or current, make sure the meter is functioning correctly.
Take a reading of a known voltage or current before accepting a zero reading.
^ When measuring current, connect the meter in series with the load.
^ Disconnect the live test lead before disconnecting the common test lead.
^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid
measuring error form outside interference.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code
Body Control Module: Application and ID Body Code
Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager
Body Code = NS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code >
Page 230
Body Control Module: Application and ID Glossary of Terms
ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System
Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler
Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC
Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic
Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET
Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger
PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature
Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum
Fluorescent Display VTSS Vehicle Theft Security System
NOTE: The following terms are used interchangeably:
- Left Front (LF) Door & Driver (DR) Door
- Right Front (RF) Door and Passenger (PASS) Door
- "Gage" and "Gauge"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System
Body Control Module: Description and Operation Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 233
Body Control Module: Description and Operation Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 234
Body Control Module: Description and Operation Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 235
Body Control Module: Description and Operation Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 236
Body Control Module: Description and Operation
Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 237
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Compass Mini-Trip Computer (CMTC)
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Auto Headlamps
On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control
the exterior lamp operation by monitoring the mode selection switch located in the headlamp
control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal
from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light
levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Battery Protection: "Park & Headlamps"
This feature provides a battery protection scheme to avoid wearing down the battery if the
customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If
the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the
ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to
be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will
enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of
sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless
Entry (RKE) actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power on) will inhibit the battery protection routine from turning off the exterior lamps as described
above.
Exterior Headlamp Control
The headlamps and parklamps are illuminated via external relays which are controlled by the body
controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the
parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is
also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp
switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays.
The position of the hi-beam select switch will determine the mode of operation.
Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams
will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time.
Headlamp Time Delay
The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and
passengers security lighting when exiting the vehicle. This feature is only available on vehicles
equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by
sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and
parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp
delay. This 45 second window is new for the NS body. Once the headlamp delay has been
activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto
headlamp or the ignition switch changes states.
Identification of System
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 238
The vehicle systems that are part of the "body" system are:
- airbag system
- chimes
- compass/mini-trip
- courtesy lamps I panel dimming
- headlamp time delay
- illuminated entry
- radio (CCD)
- information center
- mechanical instrument cluster (MIC)
- power door locks
- remote keyless entry (RKE)
- vehicle communications
- vehicle theft security system (VTSS)
- wipers
Vehicles equipped with the highline body control module can be identified by the presence of the
vehicle theft security system (VTSS). Vehicles with the midline body control module may have a
compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or
illuminated entry. Vehicles with a base body control module will not have any of these features.
Introduction
Diagnostic procedures change every year. New diagnostic systems may be added; carryover
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO
BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These
tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover
all the necessary requirements to begin a logical diagnostic path for each repair. If there is a
trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you
to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are
used to direct you alphabetically to the specific systems.
NOTE: The following terms are used interchangeably:
Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door
Mechanical Instrument Cluster (MIC)
The body control module sends the angular position of the gauges, the status of all CCD indicator
lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus
when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped)
and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions;
all other MIC features work only when the ignition is in the "run" position. On transition of the
ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all
CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The
PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine
exceeds 450 rpm.
Power Door Lock System
When the body control module (BCM) receives an input for a lock request (door lock switch, RKE,
or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount
of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM
considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck,
the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates
in the same fashion as the lock signal. The door lock switches provide a variable amount of
resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond
to that command.
Other power door lock features:
Sliding Door Memory Lock
When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on
the lock relay as described above, and will turn it on again when all sliding doors are closed.
NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the
memory lock.
Door Lock Inhibit
When the key is in the ignition and in the off position, and any door except the rear liftgate is open,
all door lock switches are disabled. The unlock switches are still functional. This protects against
locking the vehicle with the keys still in the ignition.
Automatic Door Locks
This feature can be enabled or disabled by using either the DRBIII or customer programming
method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all
doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will
operate again once all doors are closed and the speed is above 15 MPH.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 239
RKE (Remote Keyless Entry) Interface
The body control module interfaces with the RKE receiver via a one-way serial bus interface. The
RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the
transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of
the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4
individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the
BCM will ground the interface wire thereby disabling the RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the on position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Radio System
There are three radio systems available this year that will be on the CCD bus. They are the RBR,
RBN and RAZ models. The main reason they are on the bus is because of the radio remote
controls in the steering wheel. They can control volume up/down, seek up, seek down and preset
station selections. These systems also communicate with the body control module and will set a
specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers
receive their signals from the quarter speakers. Depending on the manufacture some systems will
have a Front/Rear channel system and others will have a Left/Right channel system. If one of the
main quarter speaker audio circuits experiences a short, the other speakers on that channel will
also shut down until the circuit is repaired. The radio will also set a trouble code, which is
assessible with the DRB, indicating which channel is effected.
Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS)
This passive system is designed to protect against theft. The vehicle theft security system (VTSS)
is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for
unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park
and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after
closing them. The indicator lamp in the information center will flash for 15 seconds, showing that
arming is in progress. If no monitored systems are activated during this period, the system will arm.
If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain
steadily lit during the arming process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes.
Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it
means the alarm was activated. Check the vehicle for tampering.
Manual Override - The system will not arm if the doors are locked using the manual lock control (by
hand) or if the locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows:
1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with
the power lock switch. 4. Close the driver's door.
NOTE: After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may
be a problem with the system.
System initialization is accomplished by:
1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder
to unlock/disarm position.
Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all doors are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 240
been activated.
System Self-Test
NOTE: System self-test can be entered only with the DRB.
NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system
cannot be used in a vehicle that is not equipped with a vehicle theft security system.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
Shipping Mode
By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle.
The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse.
The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping
mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will
not operate until the IOD is reconnected or the ignition switch is turned to the run/start position.
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
System Coverage
These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth
Voyager vehicles equipped with either base, midline, or highline body control modules.
Airbag Trouble Code Descriptions
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of the trouble codes. It
is not necessary to perform all of the tests in the airbag section to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
"AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must
be performed. If more than one code exists, diagnostic priority should be given to the active
code(s).
Active diagnostic trouble codes for the airbag system are not permanent and will change the
moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes
are used as a diagnostic tool.
Active Codes
An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is
currently there every time the airbag control module checks that circuit/function. It is impossible to
erase an active code; active codes automatically erase by themselves when the reason for the
code has been corrected.
With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is
detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction
is present.
Stored Codes
An airbag trouble code becomes active and stored as soon as it is detected with the exception of
the Loss of Ignition Run Only code, which is an active code only.
A "stored" code indicates there was an active code present at some time. However, the code
currently may not be present as an active code, although another active code could be.
When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even
if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes
it was active, and the number of times the ignition has been cycled since the problem was last
detected.
The minimum time shown for any code will be one minute, even if the code was actually present for
less than one minute. Thus, the time shown for a code that was present for two minutes 13
seconds, for example, would be three minutes.
If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as
the malfunction exists. When and if the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 241
malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle
count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is
erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count
reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will
continue to be a stored code.
If a malfunction is not active while performing a diagnostic test procedure, the active code
diagnostic test will not locate the source of the problem. In this case, the stored code can indicate
an area to inspect.
If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire
harness and connectors. Recheck for codes periodically as you work through the system. This
procedure may uncover a malfunction that is difficult to locate.
Airbag Diagnostic Trouble Codes
The airbag control module may report any of the following diagnostic trouble codes.
For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer
- AECM Internal Diagnostic 2
- AECM Internal Diagnostic 1
- AECM Output Driver
- AECM Stored Energy
- Internal Diagnostic 3
- Incorrect AECM
For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open
- No CCD Communication
- Driver Squib Circuit Shorted
- Passenger Squib Circuit Open
- Driver Squib Term Shorted to Battery
- Passenger Squib Circuit Shorted
- Driver Squib Term Shorted to Ground
- Pass Squib Term Shorted to Battery
- Loss of Ignition Run Only
- Pass Squib Term Short to Ground
- Loss of Ignition Run/Start
- Warning Lamp Circuit Open
- Output Driver Not Tested
- Warning Lamp Circuit Shorted
Driver Squib Circuit Open
NAME OF CODE
Driver Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring open or high resistance in clockspring
- Driver side airbag module open
- Driver airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Driver Squib Circuit Shorted
NAME OF CODE
Driver Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring short
- Driver side airbag module short
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 242
- Driver airbag line 1 shorted to line 2
- Loose, or poor connector not completely connected
Driver Squib Term Shorted to Battery
NAME OF CODE
Driver Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to voltage
- Driver airbag line 2 short to voltage
- Faulty clockspring
- Faulty airbag control module
Driver Squib Term Shorted to Ground
NAME OF CODE
Driver Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to ground potential
- Driver airbag line 2 short to ground potential
- Faulty clockspring
- Faulty airbag control module
Loss of Ignition Run Only
NAME OF CODE
Loss of Ignition Run Only
NOTE: This code becomes active as soon as the condition is detected (this is not a stored code).
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Open ignition run circuit
- Open fuse
- Ignition run circuit short to ground
- Loose or poor connection at connector terminals
Loss of Ignition Run/Start
NAME OF CODE
Loss of Ignition Run/Start
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 243
- Open ignition run/start circuit
- Open fuse
- Ignition run/start circuit short to ground
- Loose or poor connection at connector terminals
Passenger Squib Circuit Open
NAME OF CODE
Passenger Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) open
- Passenger airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Passenger Squib Circuit Shorted
NAME OF CODE
Passenger Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) short
- Passenger airbag line 1 shorted to line 2
- Loose or poor connection at connector terminals
Pass Squib Term Shorted to Battery
NAME OF CODE
Pass Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to voltage
- Passenger airbag line 2 short to voltage
- Faulty airbag control module
Pass Squib Term Shorted to Ground
NAME OF CODE
Pass Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to ground potential
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 244
- Passenger airbag line 2 short to ground potential
- Faulty airbag control module
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NAME OF CODE
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or
during a lamp check.
SET CONDITION
With the voltage on, the airbag warning lamp driver circuit is other than expected.
POSSIBLE CAUSES
- Faulty warning lamp
- Open fused ignition switch output circuit to Information Center
- Airbag warning lamp driver circuit short to ground
- Airbag warning lamp driver circuit short to voltage
- Faulty information center printed circuit board
- Loose or poor connection at connector terminal
Output Driver Not Tested
NAME OF CODE
Output Driver Not Tested
WHEN MONITORED
At ignition on.
SET CONDITION
This code may set whenever another code is set due to any short to battery or short to ground
failure of the squib circuits. If all other squib codes have been repaired and this code appears
active by itself, the problem will be an internal failure of the airbag control module.
POSSIBLE CAUSES
- Short circuit to ground or to battery in either driver or passenger airbag lines
- Defective airbag control module
Trouble Code Testing Notes
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of trouble codes. It is
not necessary to perform all of the tests to diagnose an individual code.
The body control module will set a diagnostic trouble code if a monitored input is determined to be
malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the
trouble code condition is removed, the body control module will back out the diagnostic trouble
code if the trouble code condition remains cleared for twenty ignition cycles.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This
will direct you to the specific test(s) that must be performed.
ASB Message Not Received
NAME OF CODE
ASB Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from CAB every second. If this message is not received by the BCM
for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from CAB to BCM
Airbag Message Not Received
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 245
NAME OF CODE
Airbag Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from ACM every second. It this message is not received by the BCM
for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from ACM to BCM
Battery Power to Module Disconnected
NAME OF CODE
Battery Power to Module Disconnected
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
Battery power to the BCM is disconnected while the ignition is on.
THEORY OF OPERATION
The body control module checks battery input and determines if the battery is connected.
POSSIBLE CAUSES
- In shipping mode - IOD fuse missing
- Open wire
- Blown IOD fuse
EATX PRNDL Message Test Failed
NAME OF CODE
EATX PRNDL Message Test Failed
WHEN MONITORED
When engine is running.
SET CONDITION
The engine is running above 450 rpm and the body control module has not received a transmission
PRNDL message.
THEORY OF OPERATION
The body control module will monitor the CCD bus and look for the transmission PRNDL message
whenever the engine rpm is above 450.
POSSIBLE CAUSES
- Body Control module
- Transmission control module
- CCD bus failure
- Loss of power to transmission control module
EEPROM Checksum Failure
NAME OF CODE
EEPROM Checksum Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The sum of EEPROM constants does not equal the correct value.
THEORY OF OPERATION
By using a checksum, the BCM monitors the value of each programmable constant. The code is
set if any value is incorrect.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 246
- Body Control module
Front Wiper Park Switch CKT Open
NAME OF CODE
Front Wiper Park Switch Ckt Open
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Open wire
- Wiper motor
- Body Control module
Front Wiper Park Switch CKT-Shorted
NAME OF CODE
Front Wiper Park Switch Ckt-Shorted
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Shorted wire
- Wiper motor
- Body Control module
Fuel Level Sending Circuit Error
NAME OF CODE
Fuel Level Sending Circuit Error
WHEN MONITORED
With the ignition key on and battery voltage above 10 volts.
SET CONDITION
When the BCM senses an open or short on the fuel level sensor signal circuit.
THEORY OF OPERATION
The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on
fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be
set.
POSSIBLE CAUSES
- Open wire
- Shorted wire
- Fuel level sending unit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 247
- Body control module
Internal Module Test Failed
NAME OF CODE
Internal Module Test Failed
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The body control module performs an internal check and determines the body control module is not
functioning properly.
THEORY OF OPERATION
The body control module performs internal diagnostics on demand and determines if the body
control module microprocessor is functioning properly.
POSSIBLE CAUSES
- Body control module
Left Door Key CYL Arm SW Failure
NAME OF CODE
Left Door key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Key CYL Disarm SW Failure
NAME OF CODE
Left Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Lock Switch Failure
NAME OF CODE
Left Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 248
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Left Door Unlock Switch Failure
NAME OF CODE
Left Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Liftgate Key CYL Arm SW Failure
NAME OF CODE
Liftgate Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Key CYL Disarm SW Failure
NAME OF CODE
Liftgate Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 249
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Door Mux CKT Short to GND
NAME OF CODE
Liftgate Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (Liftgate Switch MUX)
- Body control module
LT Front Door Mux Circuit Short to GND
NAME OF CODE
LT Front Door MUX Circuit Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (LF Door Switch MUX)
- Body control module
No CCD Message From PCM
NAME OF CODE
No CCD Message From PCM
WHEN MONITORED
When the ignition is in the run or start position and battery voltage is above 10 volts.
SET CONDITION
The BCM looks for engine messages over the CCD bus and does not receive a message within a
2-second period.
THEORY OF OPERATION
The body control module will monitor the engine messages after the ignition has been turned on.
POSSIBLE CAUSES
- Body control module
- Powertrain control module
- CCD Bus failure
Rear Wiper Mux Circuit Error
NAME OF CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 250
Rear Wiper MUX Circuit Error
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts.
SET CONDITION
When the rear wiper MUX circuit senses a voltage above 5.0 volts.
THEORY OF OPERATION
The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The
CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level.
The voltage level will determine the wiper function to be performed. That level will be below 5.0
volts.
POSSIBLE CAUSES
- Circuit shorted to battery
- Open CCM ground circuit
Right Door Key CYL Arm SW Failure
NAME OF CODE
Right Door Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Key CYL Disarm SW Failure
NAME OF CODE
Right Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Lock Switch Failure
NAME OF CODE
Right Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 251
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
Right Door Unlock Switch Failure
NAME OF CODE
Right Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
RT Front Door Mux CKT Short to GND
NAME OF CODE
RT Front Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below .4 volts on the RF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (RF Door Switch MUX)
- Body control module
Horn Switch Failure
NAME OF CODE
Horn Switch Failure
WHEN MONITORED
Continuously with battery connected and IOD fuse installed.
SET CONDITION
The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering
wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more
than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The
horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to
cool down.
POSSIBLE CAUSES
- Shorted horn relay control circuit
- Defective horn switch
- Defective BCM
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 252
CCD Radio
NAME OF CODE
CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume
Down Switch (Stuck) Preset Switch (Stuck)
WHEN MONITORED
Anytime ignition is on and voltage is above 10.0 volts.
SET CONDITION
When a switch is held active for longer than 20 seconds.
THEORY OF OPERATION
The BCM monitors the control switches for an active condition and performs the required radio
function. When a switch is active for longer than 10 seconds, that switch function will be disabled
until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be
set.
POSSIBLE CAUSES
- Defective remote control switch
- Shorted radio control MUX circuit
Vehicle Communication
The body system consists of a combination of modules that communicate over the Chrysler
Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the
operation of vehicle components and circuits is relayed to the appropriate module(s). Each module
receives the same information about a component or circuit as the other modules do. This
significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus
plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
+ and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board
diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle
Communications section.
Any of the following bus failure messages may be displayed.
Short to Battery - Either or both of the bus wires are shorted to the battery potential.
Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential.
Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be
open.
Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together.
No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts.
Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their
normal 2.5 volts.
No Bus Bias - The bus system has lost connection with all modules that provide bias.
Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 253
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias.
Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not
know why.
Wiper System
FRONT
The front wiper system provide the driver with normal wipe (low and high speeds), intermittent
wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a
resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on
position and the ignition is turned off, the wiper will continue to run until it reaches its park position.
Other front wiper system features:
Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay
of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay
time is doubled to provide a range time of from 1 second to 36 seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
REAR
The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics
Body Control Module: Component Tests and General Diagnostics
SELF DIAGNOSTIC TEST
To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the
TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to
the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in
the odometer windows (about five seconds) then release the
buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists
the code 999 (End Test) will momentarily appear.
INSTRUMENT CLUSTER DTC CHART
DTC .....................................................................................................................................................
.................................................... Description 110 ...............................................................................
.......................................................................................................... Memory Fault in cluster 111 .....
..............................................................................................................................................................
................... Calibration fault in cluster 905 .........................................................................................
................................................................................ No CCD bus messages from TCM 921 ..............
..............................................................................................................................................................
......... Odometer fault from BCM 940 ...................................................................................................
...................................................................... No CCD bus messages from PCM 999 ........................
..............................................................................................................................................................
.................... End of Codes
NOTE: For DTC testing see Condition Diagnostic Charts below.
CONDITIONS
Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Instrument Cluster Diagnosis
- Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Speedometer Diagnosis
- Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Tachometer Diagnosis
- Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Fuel Gauge Diagnosis
- Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Temperature Diagnosis
- Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Odometer Diagnosis
- Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis
- Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and
corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Calibration Table contains the proper calibration
points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If
any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III).
CLUSTER CALIBRATION TABLE
Speedometer .......................................................................................................................................
................................................. Calibration Point
1 ...........................................................................................................................................................
............................................... 0 mph (0 Km/h) 2 .................................................................................
..................................................................................................................... 20 mph (40 Km/h) 3 .......
..............................................................................................................................................................
................................. 55 mph (80 Km/h) 4 ...........................................................................................
.......................................................................................................... 75 mph(120 Km/h)
Tachometer .........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
............................................................... 0 rpm 2 ................................................................................
.................................................................................................................................... 1000 rpm 3 .....
..............................................................................................................................................................
................................................. 3000 rpm 4 ........................................................................................
............................................................................................................................ 6000 rpm
Fuel Gauge ..........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
......................................................... Empty(E) 2 .................................................................................
................................................................................................................................... 1/8 Filled 3 .......
..............................................................................................................................................................
............................................... 1/4 Filled 4 ...........................................................................................
............................................................................................................................ Full (F)
Temperature Gauge ............................................................................................................................
............................................... Calibration Point
1 ...........................................................................................................................................................
.......................................................... Cold (C) 2 .................................................................................
.............................................................................................................................. Low Normal 3 .......
..............................................................................................................................................................
......................................... High Normal 4 ............................................................................................
........................................................................................................................... Hot (H)
DIM TEST
When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays
will dim down. If the VF display brightness does
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics > Page 256
no change, a problem exists in the cluster.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate
sequentially If a segment in the odometer does not illuminate normally, a problem exists in the
display.
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer window, each segment of the transmission range
indicator will illuminate sequentially. If a segment in the transmission range indicator does not
illuminate normally, a problem exists in the display board.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics > Page 257
Body Control Module: Scan Tool Testing and Procedures
Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing
trouble codes, and other DRB functions.
DRBIII Error Messages
Under normal operation, the DRB will display one of only two error messages:
- User-Requested WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the scantool
manufacturer for information and assistance. This is a sample of such an error message display:
ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD
boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRBIII Does Not Power Up (Blank Screen)
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a
bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts
is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A
Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 258
Body Control Module: Service and Repair
Body Control Module Location
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4.
Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting
bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control
Module downward to disengage guide studs on Junction Block from channels on BCM mounting
bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to
engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws
holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5.
Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom
of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker
reinforcement. 8. Connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 259
Body Control Module: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge (0-300 psi)
- Test Light
- Voltmeter
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations
Fig 1 Powertrain Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 265
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 266
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 267
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 268
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 269
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 270
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 271
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 272
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 273
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 274
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 275
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 276
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 277
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 278
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 279
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 280
Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 281
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 282
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 283
Powertrain Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 284
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 285
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 286
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 287
Powertrain Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 288
Powertrain Control Module: Description and Operation
Fig 1 Powertrain Control Module
POWERTRAIN CONTROL MODULE (PCM)
The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input
signals from various switches and sensors that are referred to as PCM Inputs. Based on these
inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to
as PCM Outputs.
PCM Inputs: Air Conditioning Head Pressure
- Battery Voltage
- Brake Switch
- Camshaft Position Sensor
- Crankshaft Position Sensor
- Engine Coolant Temperature Sensor
- Heated Oxygen Sensors (Upstream and Downstream)
- Knock Sensor
- Manifold Absolute Pressure (MAP) Sensor
- SCI Receive
- Speed Control System Controls
- Throttle Position Sensor
- Transaxle Park/Neutral Position Switch (automatic transaxle)
- Transmission Control Module
- Vehicle Speed Sensor
PCM Outputs: Air Conditioning Clutch Relay
- Automatic Shutdown (ASD) Relay
- Data Link Connector
- Electric EGR Transducer
- Fuel Injectors
- Fuel Pump Relay
- Generator Field
- Idle Air Control Motor
- Ignition Coil
- Leak Detection Pump
- Malfunction Indicator (Check Engine) Lamp
- Proportional Purge Solenoid
- Radiator Fan Control Module
- Speed Control Solenoids
- Tachometer Output
- Torque Converter Clutch Solenoid (3 speed transmission)
- Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 289
Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air
conditioning and speed control systems. The PCM changes generator charge rate by adjusting the
generator field.
The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage
- Engine coolant temperature
- Exhaust gas content (oxygen sensors)
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
The PCM adjusts ignition timing based on the following inputs: Barometric pressure
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
The PCM also adjusts engine idle speed through the idle air control motor based on the following
inputs: Air conditioning select switch head pressure
- Brake switch
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
- Vehicle distance (speed)
Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump
relays are located in the Power Distribution Center (PDC).
The camshaft position sensor and crankshaft position sensor signals are sent to the PCM.
If the PCM does not receive both signals within approximately one second of engine cranking, it
deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut
off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump.
PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery
voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor
and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute
pressure sensor, throttle position sensor and engine coolant temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 290
Powertrain Control Module: Service and Repair
Fig 29 Power Distribution Center Retaining Screws
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29).
Fig 30 Battery Heat Shield
3. Remove heat shield from battery (Fig 30).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 291
Fig 31 Battery Clamp
4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle.
Fig 32 PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward
to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 292
Fig 33 PCM 40 Way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33).
Remove both way connectors.
Fig 34 PCM Removal/Installation
9. Remove 3 screws holding PCM to fender (Fig. 34).
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting
screws. 3. Install PDC bracket. 4. Install battery.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In
addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data
must be updated to enable starting.
For ABS and Air Bag systems:
ACTION:
1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules.
For SKIM theft alarm:
ACTION:
1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in
secured access mode, by using the appropriate PIN code for this vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 293
3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 299
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 300
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 301
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 302
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 303
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 304
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 305
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 306
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 307
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 308
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 309
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 310
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 311
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 312
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 313
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 314
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 315
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 316
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 317
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 318
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 321
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 326
Fuel Pump Relay: Diagrams
Fuel Pump Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 327
Fuel Pump Relay: Testing and Inspection
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 328
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 334
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 335
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 336
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 337
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 338
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 339
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 340
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 341
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 342
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 343
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 344
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 345
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 346
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 347
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 348
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 349
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 350
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 351
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 352
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 353
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Powertrain Management > Relays and Modules Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 356
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Powertrain
Management/Computers and Control Systems/Testing and Inspection/Diagnostic Trouble Code
Tests and Associated Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test CODE TO TC TEST CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 361
Air Bag Control Module: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 362
Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The
ACM monitors the system to determine the system readiness. The ACM contains on-board
diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs.
The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or
serious injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Airbag Module Locations
Driver And Passenger Airbag Modules The Driver Airbag Module is located in the center of the
steering wheel. The Passenger Airbag Module is located in the instrument panel above the glove
box. The Driver Airbag Module cover contains the horn switch, inflator device, and a fabric bag.
The airbag cover/horn switch is serviced separately from the inflator and bag components. The
Passenger Airbag Module is serviced as an assembly.
WARNING: WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION, THE
FOLLOWING MUST BE REPLACED: COMPLETE STEERING COLUMN ASSEMBLY
- LOWER STEERING COUPLER
- STEERING WHEEL
- STEERING COLUMN CLOCKSPRING
- DRIVER AIRBAG COVER/HORN SWITCH
- DRIVER AIRBAG MODULE
- PASSENGER AIRBAG MODULE
- UPPER INSTRUMENT PANEL WITH PAD.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 363
Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 364
Air Bag Control Module: Service and Repair
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the
reserve capacitor in the Airbag Control Module (ACM) to
discharge.
2. Remove forward lower console from instrument panel.
Heat Duct
3. Remove screw holding lower heat duct to instrument panel support. 4. Remove heat duct from
instrument panel.
5. Remove two bolts holding top of right support to instrument panel. 6. Remove two bolts holding
bottom of right support to floor pan. 7. Separate right instrument panel support from vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 365
ACM Connectors
8. Disconnect two wire connectors from ACM.
9. Remove four bolts holding the ACM bracket assembly to floor.
10. Remove the ACM from vehicle.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET
THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD
NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET
INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM
For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with
the proper screws and tighten to 805 to 11.9 N.m (75 to 105 in. lbs.) torque. Do not connect battery
negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 370
Engine Compartment Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 371
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 382
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 383
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 389
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 390
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 393
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 394
Control Module: Locations Power Distribution Center
Junction Block
Power Distribution Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 395
Fuse Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 398
Control Module: Diagrams Control Module, A/T
Part 1 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 399
Part 2 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 400
Part 3 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 401
Part 4 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 402
Part 5 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 403
Part 6 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 404
Part 7 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 405
Part 8 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 406
Part 9 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 407
Part 11 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
410
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
411
Control Module: Description and Operation TCM Inputs
General Information
GENERAL INFORMATION
The TCM receives input information and continuously processes this information through its logic
circuits to perform all of the control functions that it is designed to perform. However, some of these
control functions are internal to the TCM, while other control functions are performed when the
TCM provides some type of output signal to another control device or module. The following is a
description of TCM input sensors and output devices.
The TCM uses various inputs to determine when to upshift or downshift and when to engage or
disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous
feedback data for controlling shift quality. Without any input, the TCM has no way to determine the
state of the transaxle and cannot control its operation as designed.
Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other
components through the CCD Bus.
DIRECT (HARD-WIRED) TCM INPUTS
- Battery Feed
- Ignition RUN Signal
- Cranking Signal
- Throttle Position Sensor (TPS) Signal
- Engine speed signal (Distributor or DIS Crankshaft Position Sensor)
- Input Speed Sensor Signal
- Output Speed Sensor Signal
- Transmission Range Sensor**(Includes Transmission Temperature Sensor)
- Transmission Control Relay (Switched Battery)
- L/R Pressure Switch Signal
- 2-4 Pressure Switch Signal
- O/D Pressure Switch Signal
- Park/Neutral Position Switch*
- PRNDL Switch*
- Torque Reduction Request Line (TRD Link)
INDIRECT (CCD BUS) TCM INPUTS
- Target Idle Speed
- Engine Coolant Temperature (ECT) Sensor
- Battery Temperature Sensor*
- Brake Switch
- Engine and Body Identification
- Engine Speed (Verifies Direct Input Engine Speed Signal)
- Speed Control ON/OFF Switch
- Speed Control Set Speed
- A/C Clutch Engagement
- Vehicle Identification Number (VIN)
- Manifold Absolute Pressure (MAP) Sensor
- Torque Reduction Confirmation Response
- Relative Throttle Position (Beginning in 1998)
*: UP TO 1995 **: BEGINNING IN 1996
Battery and Ignition (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
412
BATTERY
A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced
and also fed to the contact side of the Transmission Control Relay. On vehicles with an original
TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the
adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or
road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated
per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in
memory; therefore, a quick learn or road test is not necessary.
IGNITION
When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START
(CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above
approximately 26 volts or below 8 volts, the TCM automatically powers down which results in
limp-in symptoms.
Throttle Position Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
413
The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift
quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5
volt supply and ground for the sensor. Target idle speed is compared against actual engine speed
to determine the learned TPS value for closed throttle idle. This is done to correct for differences in
system voltage and sensor tolerances.
If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by
substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier
vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts
that are vehicle speed dependent.
NOTE: Refer to TSB 18-13-94 if erratic shifting is evident.
Input Speed Sensors and Output Speed Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
414
The input speed sensor provides information to the TCM on how fast the torque converter turbine is
spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing.
The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input
clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is
induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this
information as input shaft rpm. This information is also compared to the output shaft speed and the
engine speed signal to determine the following:
- Planetary gears operating ratio
- Torque converter clutch slippage
- Torque converter element speed ratio
The output speed sensor is located on the same side of the transaxle case as the input speed
sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal
from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the
output speed sensor signal is received by the TCM, the signal is compared to the input speed
signal to determine gear ratio, detect clutch slippage, etc.
Pressure Switches (Hard-Wired)
The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack
Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits.
The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at
approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists
or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic
pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the
shift lever electrical signal is incorrect.
Transmission Temperature Sensor (Hard-Wired) (Beginning 1996)
The Transmission Temperature Sensor is used to monitor the temperature of the transmission
fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based
on the resistance value of the temperature sensor located in the Transmission Range Sensor
(TRS). The primary temperature inputs used by the TCM are the Transmission Temperature
Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be
running to get accurate temperature readings.
NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral
position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position
switch.
If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination
of inputs. The calculated fluid temperature is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
415
continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF.
On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the
vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a
value between the battery temperature and engine coolant temperature signals received from the
PCM over the CCD Bus.
The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The
temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS,
non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a
heat transfer equation that uses engine coolant temperature, battery/ambient temperature and
extended time off (if known) at start up.
Transmission Shift Scheduling
Once the engine is started, the TCM updates the transmission oil temperature based on the
following to determine an estimated oil temperature during vehicle operation (if a calculated oil
temperature is being used):
- Torque converter slip speed
- Vehicle speed
- Engine coolant temperature
- Battery/ambient temperature
Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal
operation. However, if a transmission oil cooler is added, a transmission is overfilled, a
transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the
calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be
inappropriate for the current conditions.
The key highlights of the various shift schedules are as follows:
Extreme Cold: Oil temperature at start up below -16° F.
- Goes to "Cold" schedule above - 12°F oil temperature
- Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent
shifts)
Cold: Oil temperature at start up above - 12 ° F and below 36°F
- Goes to "Warm" schedule above 40° F oil temperature
- Delayed 2-3 upshift (approximately 22 - 31 MPH)
- Delayed 3-4 upshift (45 - 53 MPH)
- Early 4-3 coastdown shift (approximately 30 MPH)
- Early 3-2 coastdown shift (approximately 17 MPH)
- High speed 4-2, 3-2, 2-1 kickdown shifts are prevented
- No EMCC
Warm: Oil temperature at start up above 36° F and below 80° F
- Goes to "Hot" schedule above 80°F oil temperature
- Normal operation (upshift, kick-downs and coast-downs)
- No EMCC
Hot: Oil temperature at start up above 80° F
- Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY)
- Normal operation (upshifts, kick-downs and coast-downs)
- Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH)
Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F
- Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH
97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F
- Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH)
- Delayed 3-4 upshift (41 - 48 MPH)
- 3rd gear FEMCC from 30 - 48 MPH
- 3rd gear PEMCC from 27 - 31 MPH
Super Overheat: 97 MY - Oil temperature above 240°F
- Goes back to "Overheat" below 240 ° F oil temperature
- All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
96 and prior MY - Oil temperature above 260°F
- Goes back to "Overheat" below 260 ° F oil temperature
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
416
- All "Overheat" shift schedule features apply
- 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
Causes for operation in the wrong temperature shift schedule:
Extreme Cold or Cold shift schedule at start up:
- Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only)
- Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only)
- Defective PCM (calculated oil temperature vehicles only)
- Defective sensor circuit (TRS equipped only)
Overheat or Super Overheat shift schedule after extended operation:
- Operation in city traffic or stop-and-go traffic
- Engine idle speed too high - Stuck AIS motor
- Aggressive driving in low gear
- Trailer towing in OD gear position (use "3" position if frequent shifting occurs)
- Cooling system failure causing engine to operate over 230° F
- Engine coolant temperature stays low too long - If engine coolant temperature drops below 150°
F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will
cause the transmission to overheat.
- A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC
disengaged will cause the transmission to overheat.
- Transmission fluid overfilled (TRS equipped only)
- Transmission cooler or cooler lines restricted (TRS equipped only)
- Defective sensor circuit (TRS equipped only)
Engine Speed (Hard-Wired and CCD Broadcast)
The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor,
as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is
required to provide immediate information for use by the TCM control logic. The CCD engine speed
data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid.
MAP Sensor (CCD Broadcast)
The MAP Sensor provides engine load input directly to the PCM, which determines engine torque
load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The
TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades.
Engine Idle Speed (Hard-Wired and CCD Broadcast)
The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle
speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual
engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle.
Brake Switch (CCD Broadcast)
The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque
converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control
when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
417
Battery/Ambient Temperature Sensor (CCD Broadcast)
The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD
broadcast information is used to control charging system, engine and transaxle operation. The
TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM
detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of
the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the
Battery Temperature signal along with engine coolant temperature to calculate the temperature.
Shift Lever Position (SLP)
The TCM identifies the position of the manual lever by comparing the current switch positions of
the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The
primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle
with the presence of an invalid or transition input code. The SLP logic function screens the input
codes from the switches and provides an SLP output signal to control actual gear selection.
Inputs include the codes indicated by the TRS current shift lever position, pressure switch
indications and speed ratio data from the input to most of the other functions in the TCM.
The identified position is stored in memory. The current switch position is determined by sensing
the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM
receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the
Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD
Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on
the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated.
CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with
sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is
a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse
but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed
data will not agree with the expected results for shift lever position = "OD." Therefore, it is important
to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes.
It is extremely important that accurate shift lever position data be available to the TCM. The
accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test,
performed on the DRB Scan Tool, passes without fail.
Torque Management Signal (CCD Broadcast)
With some engines, the TCM sends a direct input, torque management request signal to: the PCM.
This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque
management request signal is used in order to reduce the torque applied in the 2-4 and OD
clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel
injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine
during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a
very short time period. The PCM sends a confirmation of the request to the TCM over the CCD
Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually
be set.
The torque management signal is basically a 9-volt supply to the PCM. A torque management
request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is
called TRD link, which stands for "Torque Reduction Link."
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
418
PRNDL Switch (Hard-Wired)
NOTE: Used up to 1995 (Early 96 NS)
The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along
with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The
TCM uses this input to determine what gear range and shift pattern to use.
Park/Neutral Position Switch (Hard-Wired)
NOTE: Used up to 1995 and early 96 NS
The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and
Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position
Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both
switches must be closed to operate the back-up lamps.
Transmission Range Sensor (Hard-Wired)
The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission
Range Switch that are found on vehicles prior to the 1996
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
419
MY. This sensor allows for accurate transaxle gear position identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
420
Control Module: Description and Operation TCM Outputs
General Information
The TCM directly controls the following:
- Transmission Control Relay
- Solenoid pack
- Torque management requests to the PCM
Additionally, the TCM broadcasts the following information over the CCD Bus for use by other
vehicle control systems (Indirect Outputs):
- Communication with the DRB Scan Tool for diagnostics
- Shift lever position to the BCM
- Shift lever position to the shift lever display
- Transmission oil temperature to the PCM in order to activate the cooling fans
- Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus
- Limp - in Status
- Transmission Temperature
- In-gear position
NOTE: MIL request is from the PCM.
Transmission Control Relay
The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal
electronic circuits are all working properly. If the self-test results are good, then the TCM sends
battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts,
which then supply battery voltage to the TCM, the four solenoids and the three pressure switches
in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to
the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then
stored in memory. The Transmission Control Relay is located in various places depending on the
vehicle model.
Solenoid and Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
421
When the Transmission Control Relay contact points are closed, the solenoid assembly receives
electrical power. The TCM can then operate the solenoids, as determined by its programming. The
relay provides power to all four solenoids through a single wire. This means that all the solenoids
have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids,
however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is
needed.
The assembly is mounted to the outside of the transaxle case, under a sound shield protective
cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel
plate. There are also small solenoid valve filters used to protect the valves from contamination.
These filters are not replaceable. If the valve body and solenoid pack have been heavily
contaminated, the solenoid pack should be closely inspected to determine if it should be replaced.
The solenoid pack is not a serviceable unit.
The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control
Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to
four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the
solenoid/valves is that they directly control the application of a clutch. In other electronically
controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through
normal hydraulic valving. The solenoid assembly also contains pressure switches that feed
information to the TCM.
Vehicle Speed Signal
The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor
signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output
speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM.
The PCM receives this signal and converts it to a signal that can be used by the Body Control
Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent
over the CCD Bus.
Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
422
On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive
lockout function operated by a button on the instrument panel. The lockout feature makes driving
smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the
transaxle may shift in and out of overdrive, causing unnecessary shifting.
NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ
vehicles use a momentary contact switch.
Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and
provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to
normal operation and turn off the overdrive lockout lamp.
With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If
the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3
upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an
earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the
overdrive lockout switch or selection of the "3" position.
Electronic Pinion Factor
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRB Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration:
- If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when moving
- Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification
Use the following procedures to set the electronic pinion factor using the DRB Scan Tool:
- Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will
display the current tire size.
- If the tire size is incorrect, depress the Enter key and then select the correct size.
- Depress the Page Back key to exit the reset procedure.
Shifter/Ignition Interlock
The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the
automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The
interlock system locks the floor mounted shift lever into the PARK position whenever the ignition
switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the
shifter is unlocked and will move into any position. The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK
position.
Shift Position Indicator
The shifter position indicator is located in the instrument cluster. The shifter position indicator
outlines with a box the gear position the transaxle manual valve lever is in.
The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM
on the position of the transaxle manual valve lever. The TCM receives the switch signal and
processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the
CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster.
Autostick
Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When
the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using
before Autostick was activated. Moving the shifter to the left (towards the driver) causes a
downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument
cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while
in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift
schedule.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information > Page
423
Automatic Overrides
Some shifts are executed automatically or prevented Automatic shifts will occur under the
illustrated conditions:
Additionally, under certain circumstances, the TCM may take over and override the autostick
features, for example, under the following conditions:
- Autostick switch input errors
- Error overspeed
- Engine overheating
- Transmission overheating Autostick shifts are not permitted under the illustrated conditions:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page 426
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 430
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Transmission and Drivetrain > Relays and
Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 431
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Relays and Modules > Relays and Modules - Wiper and Washer Systems > Wiper Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch
Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch
REMOVAL
1. Open the front door.
Front Door Ajar Switch
2. Remove the screw holding the door ajar switch to the door B-pillar. 3
Remove the door ajar switch from the B-pillar.
4. Disconnect the wire connector from the back of the ajar switch and remove the switch.
INSTALLATION
- For installation, reverse the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Door
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page
442
Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch
REMOVAL
1. Release the sliding door latch and allow back of the door to pop open.
Sliding Door Ajar Switch
2. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar
switch from quarter panel opening. 3. Disconnect the wire connector from the back of the ajar
switch. 4. Remove the sliding door ajar switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Hood
Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger
switch from top of the radiator closure panel.
Hood Ajar Switch
3. Disconnect the trigger switch from the wire connector and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch
Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch
REMOVAL
1. Remove the door trim and water shield. 2. Close the door window. 3. Disconnect the door lock
cylinder switch wire connector from the door harness and wiring clip from the impact beam. 4.
Remove the outer handle from the door.
Door Lock Cylinder Switch
5. Disengage the lock tab holding switch to the back of the lock cylinder. 6. Remove the switch
from the door handle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment > Lock
Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch > Page 450
Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch
REMOVAL
1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside
latch release handle.
Liftgate Cylinder Lock Switch
4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Description and Operation
Remote Switch: Description and Operation
SYSTEM OPERATION
Remote Radio Switch Operational View
A remote radio control switch option is available on LXI models sold in North America with the
AM/FM/ cassette/S-band graphic equalizer with CD changer control feature (RBN sales code), or
the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two
rocker-type switches are mounted on the back (instrument panel side) of the steering wheel
spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset
station advance functions. The switch on the right spoke is the volume control switch and has
volume up, and volume down functions.
These switches are resistor multiplexed units that are hard-wired to the Body Control Module
(BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision
Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended.
For more information on the operation of the remote radio switch controls, refer to the owner's
manual in the vehicle glove box.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 454
Remote Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the
steering wheel.
Remote Radio Switches
Remote Radio Switches Test
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right (Left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check
for continuity between the ground circuit cavity of the switch wire harness connector and a good
ground. There should be continuity If OK,
go to Step 6. If not OK, repair the open circuit as required.
6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check
for continuity between the radio control circuit
cavity of the remote radio switch wire harness connector and a good ground. There should be no
continuity. If OK, go to Step 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the BCM wire harness
connector. There should be continuity. If OK, refer to the Powertrain Management/Computer and
Control Systems/proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK,
repair the open circuit as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 455
Remote Switch: Service and Repair
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag
system capacitor to discharge before further service. 2. From the underside of the steering wheel,
remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the
airbag module away from the steering wheel far enough to access the wire harness connectors on
the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness
connectors from the back of the airbag module. 5. Remove the driver side airbag module from the
vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness
connector from the remote radio switch (s). 8. Remove three screws securing steering wheel rear
cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side
of switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed and driver in drivers
seat.
INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be
careful to index them correctly before pressing them into place.
- Tighten the airbag module mounting screws to 10.2 N.m (90 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger)
Switch
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch
REMOVAL
1. Remove the liftgate latch from the vehicle. 2. Disconnect the wire connector from the liftgate ajar
switch.
Liftgate Ajar Switch
3. Remove the screw holding the ajar switch to the liftgate latch and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Accessories and Optional Equipment >
Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger)
Switch > Page 460
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Lock Cylinder Switch
REMOVAL
1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside
latch release handle.
Liftgate Cylinder Lock Switch
4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Hood Switch / Sensor >
Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger
switch from top of the radiator closure panel.
Hood Ajar Switch
3. Disconnect the trigger switch from the wire connector and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Door Lock Switch
> Component Information > Testing and Inspection
Power Door Lock Switch: Testing and Inspection
1. Remove door lock switch bezel assembly from door. 2. Disconnect wire connector from back of
door lock switch. 3. Depress switch to LOCK position.
Door Lock Switch
4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK
position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the
parameters shown replace the door lock switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams
Power Mirror/Window Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Testing and Inspection > Mirror Switch Test
Power Mirror Switch: Testing and Inspection Mirror Switch Test
1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch
connector.
Mirror Switch Test
3. Using a ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror
Switch Continuity Chart. 4. If results shown in the chart are not obtained, replace the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Testing and Inspection > Mirror Switch Test > Page 474
Power Mirror Switch: Testing and Inspection Side View Mirror Switch Stuck
The mirror switches in the instrument panel have normally open contacts when in their inactive
state. The left/right rocker switch has a center-off detent. If this switch is actuated to either side, it
then becomes connected to the P73/P70, circuits which are the mirror motor common connections.
No faults will result from this action by itself. If one of the other switch contacts from the round
portion of the switch becomes accidentally closed, It can cause problems such as both mirrors
operating at the same time in the vertical or horizontal modes.
Turn ignition switch ON: If two mirror switch contacts, from the round portion, are stuck in the
closed position, and the left/right portion is actuated to either side, a mirror motor will become
actuated. This will drive the motor to its stop, where it will keep ratcheting until a switch contact is
released or the ignition is turned to OFF. Replace the mirror switch assembly to correct this
condition.
- With the ignition switch in the ON or the OFF position: If only one mirror switch contact is stuck in
the closed position, the mirror motor will not become actuated. During an ignition switch recall of a
driver 5 chosen position, the Memory Seat/Mirror Module will attempt to drive the mirror motor only
if:
- The closed switch contact was the same as the desired direction
- Until the lack of a signal seen by the module shuts off the drive to the motor
The Memory Seat/Mirror Module will shut off the drive to the desired motor. It is possible that a
single stuck contact could place an opposite mirror or direction into a series connection. This would
run the connected motors at approximately half speed. Replace the mirror switch assembly to
correct this condition.
Mirror Mechanization
Mirror Mechanization Table
The 25-way connector at the Memory Seat/Mirror Module (under the driver's seat) and the mirror
mechanization show that both mirrors use the same functions. The rheostat for position sensing
utilizes the wire from the module to the mirror as both feed and sense line on the same wires, D
and F. The ground return wire, E, stands alone.
The mirror motors for each side use a common connection, B, which becomes automatically
connected to the proper polarity power connection during either manual (through the mirror switch)
or recall (through the Memory Seat/Mirror Module) modes of operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch
Power Mirror Switch: Service and Repair Power Mirror Switch
Power Mirror Switch
REMOVAL
1. Remove instrument cluster bezel. 2. Disconnect wire connector from back of power mirror
switch. 3. Disengage lock tabs above and below the mirror switch. 4. Pull power mirror switch from
headlamp switch bezel. 5. Remove power mirror switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch > Page 477
Power Mirror Switch: Service and Repair Power Mirror Switch Lamp
Power Mirror Switch Lamp
REMOVAL
1. Remove instrument cluster bezel. 2. Rotate bulb socket counter clockwise one quarter turn. 3.
Pull bulb socket from back of power mirror switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Description and Operation
Power Seat Switch: Description and Operation
SYSTEM OPERATION
Seat and Recliner Switches The seat and recliner switch assembly is mounted outboard on the
seat side-shield. Press and hold the desired seat or recliner switch to effect movement. The
Memory Seat/Mirror Module (MSM Module) will drive a maximum of 2 motors at a time in a given
direction. If conflicting directions are requested, the priority for response will be as follows: Seat Track Rearward
- Seat Front Down
- Seat Rear Down
- Recliner Rearward
- Seat Track Forward
- Seat Front Up
- Seat Rear Up
- Recliner Forward
The inputs from these switches to the MSM Module is a current limited battery source fed by the
MSM Module. This protects the MSM Module printed circuit board traces from acting as fuses. All
of these switch contact inputs to the module are normally closed to ground, except when actuated.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Description and Operation > Page 481
Power Seat Switch: Testing and Inspection
1. Remove power seat switch from seat.
Power Seat Switch Test
2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the
switch positions, replace switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation
Seat Heater Switch: Description and Operation
SYSTEM OPERATION
The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The
two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective
Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both
the driver and the front seat passenger can select a preferred seat heating mode.
Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat
that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If
either switch or LED is faulty, the switch must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 485
Seat Heater Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion
side cover. Check for continuity between the ground circuit cavity of the switch wire harness
connector
and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit
as required.
3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position,
disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open
circuit as required.
4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK,
replace the faulty switch.
5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 486
Seat Heater Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755),
gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect
wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out
switch from rear of switch bezel. 5. Remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Description and Operation
Seat Memory Switch: Description and Operation
SYSTEM OPERATION
Memory Selector Switches The memory selector switches are mounted on the driver's door trim
panel within easy reach of the driver. They provide a means to set or recall either of two positions
of seat and recliner, and the side view mirrors as chosen by the driver.
The inputs from these switches to the memory seat/mirror module is a ground level signal. 1.
Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and
release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press
any switches for 10 seconds. 4. To program the second driver's position, follow the above
sequence. 5. To recall either of the programmed positions momentarily press and release either
memory selector switch 1 or 2.
Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing
requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum
hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must
be met for proper operation of the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Description and Operation > Page 490
Seat Memory Switch: Testing and Inspection
To test the memory selector switch:
1. Remove the memory selector switch. Refer to removal procedure.
Memory Selector Switch Continuity
2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Description and Operation > Page 491
Seat Memory Switch: Service and Repair
REMOVAL
1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel.
2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Description and Operation
Brake Fluid Level Sensor/Switch: Description and Operation
A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low
fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp
circuit. This switch does not disable the ABS system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Brake Fluid
Level Sensor/Switch > Component Information > Description and Operation > Page 496
Brake Fluid Level Sensor/Switch: Service and Repair
The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for
replacement of the brake fluid level sensor.
Fluid Level Sensor Electrical Connection
1. Remove wiring harness connector from brake fluid reservoir level sensor.
Master Cylinder Brake Fluid Level Sensor
2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With
retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master
cylinder brake fluid reservoir. 4. Insert the replacement brake fluid level sensor into brake fluid
reservoir. Be sure sensor is pushed in until retaining tabs lock it to the brake fluid
reservoir.
5. Connect the vehicle wiring harness connector to the brake fluid level sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side > Page 501
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 502
Traction Control Switch: Testing and Inspection
REMOVAL AND INSTALLATION
Traction Control Switch Connector
1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading
between pins. Refer to Switch Continuity Table.
Switch Continuity Table
Switch position - Continuity between Actuated - Pins 1 And 3 Illumination - Pins 2 And 3
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 503
Traction Control Switch: Service and Repair
Over Steering Column Bezel
REMOVAL
1. Remove the over steering column bezel. 2. Remove the two screws attaching traction control
switch to the bezel.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Resistance 900 - 1,300 ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications > Page 508
Wheel Speed Sensor: Mechanical Specifications
Total Indicator Run Out Allowed 0.006 in
Front Air Gap 0.014 - 0.059 in
Rear Air Gap 0.020 - 0.054 in
To Axle Or Steering Knuckle Mounting Bolt 105 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 511
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Front > Page 514
Wheel Speed Sensor: Diagrams Rear
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Page 515
Wheel Speed Sensor: Description and Operation
Front Wheel Speed Sensor
Rear Wheel Speed Sensor (FWD)
One Wheel Speed Sensor (WSS) is located at each front and rear wheel of the vehicle. The wheel
speed sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is
generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the
stationary magnetic wheel speed sensor. The CAB converts the AC signal generated at each
wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate
hydraulic pressure via the HCU to prevent the wheel(s) from locking.
The front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is
part of the driveshafts outboard constant velocity joint. The rear wheel speed sensor is mounted
through the rear axle, rear brake support plate and directly to the rear bearing. The rear tone wheel
on a front wheel drive vehicle is an integral part of the rear wheel hub/bearing assembly. If
damaged though, the rear tone wheel on a front wheel drive vehicle can be replaced as a individual
component of the rear hub/bearing assembly. The wheel speed sensor air gap is NOT adjustable.
The rear tone wheel on a all wheel drive vehicle, is part of the outboard constant velocity joint on
the rear driveshaft.
The four wheel speed sensors are all serviced individually, but the front tone wheel on all vehicles
and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear
driveshaft outboard constant velocity joint.
Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's
wheels and tires must all be the same size and type to generate accurate signals. Variations in
wheel and tire size can produce inaccurate wheel speed signals, which can cause false ABS cycles
to occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Diagrams > Page 516
Wheel Speed Sensor: Testing and Inspection
CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake
System are different then those used on past models of this vehicle equipped with antilock brakes.
Reduced braking performance will result if this part is used on earlier model vehicles and an
accident could result. Do not use on pre-1998 model year vehicles.
Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or
broken teeth, this can cause erratic speed sensor signals.
Tonewheels should show no evidence of' contact with the wheel speed sensors. If contact was
made, determine cause and correct before replacing the wheel speed sensor.
Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Replace drive
shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification.
Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their
mounting surfaces and should not rotate independently from the mounting surface.
Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the
speed sensor head and the tone wheel to ensure it is at specification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
Front Speed Sensor Cable Channel Bracket
3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame
rail.
CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not
to damage pins on connector
Speed Sensor Cable To Vehicle Wiring Harness
4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect
speed sensor cable from vehicle wiring harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 519
Front Wheel Speed Sensor Attaching Bolt
5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor
head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON
SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free.
Front Wheel Speed Sensor Cable Routing
7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front
wheel speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in
this section may result in contact with moving parts and/or over extension of cables, resulting in an
open circuit.
1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure
speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut
tower.
CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the
channel bracket.
2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching
the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4.
Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to
steering knuckle on the rearward side of the
stabilizer bar link.
5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor
attaching bolt to a torque of 12 Nm (105 inch lbs.). 6. Check the air gap between the face of the
wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Rear
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to
damage pins on the electrical connectors. Also inspect connectors for any signs of previous
damage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 520
Rear Speed Sensor Cable Connection To Vehicle Wiring Harness
3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from
vehicle wiring harness.
CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during removal of the speed sensor cable.
Speed Sensor Cable Attachment To Brake Flex Hose
4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips.
Right Rear Speed Sensor Cable Routing
5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the
axle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 521
Rear Speed Sensor Routing Brackets And Clips
6. Remove the 2 rear wheel speed sensor cable/ brake tube routing clips. Then un-clip the speed
sensor cable from the routing clips on rear brake
tube.
CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor
head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the
sensor from side to side until free.
Rear Wheel Speed Sensor Attaching Bolt
7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not
come loose, do not use pliers. Tap with screw driver
and hammer.
8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed
sensor assembly from vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in
this section may result in contact with moving parts and/or over extension of cables, resulting in an
open circuit.
1. Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must
be fully seated into the bearing flange.
2. Install the wheel speed sensor head to bearing Range attaching bolt. Tighten the attaching bolt
to a torque 12 Nm (105 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor
and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle.
The rear wheel speed sensor cable should be routed
under the rear brake tube.
CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during installation of the wheel speed
sensor cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 522
5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear
speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket.
CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed
sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the
vehicle wiring harness, do not force the connectors together. If the connectors are forced together,
damage to the connectors will occur.
7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable
connector is fully seated and locked into vehicle wiring
harness connector.
8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into
the body hole. 9. Install the tire and wheel assembly on vehicle.
10. Road test vehicle to ensure proper operation of the base and ABS braking systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 523
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and
tire assembly. 3. Remove rear brake drum from the hub/bearing assembly.
Rear Wheel Speed Sensor
4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing assembly.
Rear Hub/Bearing Mounting Bolts
5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle.
Removing Rear Hub/Bearing From Axle
6. Remove the hub/bearing assembly from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 524
Tone Wheel Removal From Hub/Bearing Assembly
7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage
by the vise jaws. Mount the hub/bearing assembly
in a vise. Using Puller, Special Tool C-4693 or equivalent installed as shown remove the tone
wheel from the hub/bearing assembly.
INSTALL
Installing Tone Wheel On Hub/Bearing Assembly
1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3 or
equivalent. Position Driver, Special Tool 6908-1
or equivalent with undercut side facing up on top of the tone wheel.
Correctly Installed Tone Wheel
2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3.
Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the
rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the
rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts
into hub/ bearing assembly. Tighten the 4 bolts in a
criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto
flange of rear axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Brakes and Traction Control > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 525
6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 7. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
8. Check the air gap between the face of the wheel speed sensor and the top surface of the
tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
9. Install the brake drum onto the rear hub/bearing assembly.
10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust
the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 531
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 532
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 533
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 534
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 535
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cooling System > Engine - Coolant
Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Gauge Sending Unit
........................................................................................................................................................... 7
Nm (60 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Description and Operation
Brake Switch (Cruise Control): Description and Operation
SYSTEM OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is
mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting
bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Description and Operation > Page 543
Brake Switch (Cruise Control): Testing and Inspection
Fig. 21 Stop Lamp Switch
1. Remove the stop lamp switch, refer to Stop Switch Removal/Installation. Disconnect connector
from stop lamp switch. Using an ohmmeter, switch
continuity may be checked as follows:
2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch
plunger depressed, there should be continuity:
- Between Pin 1 and Pin 2.
- Between Pin 3 and Pin 4.
4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. 5.
See Stop lamp switch adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Brake Switch (Cruise
Control) > Component Information > Description and Operation > Page 544
Brake Switch (Cruise Control): Service and Repair
REMOVAL
Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a
counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from
bracket. Disconnect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch
with the plunger facing forward in car. There is an index key on the switch that mates with the
bracket slot at the top of the square hole. Align key and push switch into square hole in bracket
while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise
approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is
released. Pull back on the pedal to assure correct adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Locations
Speed Control Switches
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Clutch Switch, Cruise
Control > Component Information > Locations > Page 548
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 552
Cruise Control Switch: Description and Operation
SYSTEM OPERATION
There are two separate switch pods that operate the speed control system. The
steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner 5 manual
for more information on speed control switch functions and setting procedures.
When speed control is selected by depressing the ON switch, the PCM allows a set speed to be
stored in RAM for speed control. To store a set speed, depress the SET switch while the vehicle is
moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes
cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral.
The speed control can be disengaged manually by: Stepping on the brake pedal
- Depressing the OFF switch
- Depressing the CANCEL switch.
NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored
in the PCM.
For added safety,the speed control system is programmed to disengaged for any of the following
conditions: An indication of Park or Neutral
- An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged)
- Excessive engine rpm (indicates that the transmission may be in a low gear)
- The VSS signal increases at a rate of 10 mph per second (indicates that the coefficient of friction
between the road surface and tires is extremely low)
- The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have
decelerated at an extremely high rate)
- If the actual speed is not within 20 mph of the set speed
The previous disengagement conditions are programmed for added safety.
Once the speed control has been disengaged, depressing the ACCEL switch when speed is
greater than 25 mph restores the vehicle to the target speed that was stored in the PCM.
NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM.
While the speed control is engaged, the driver can increase the vehicle speed by depressing the
ACCEL switch. The new target speed is stored in the PCM when the ACCEL is released. The PCM
also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for
each momentary switch activation of the ACCEL switch. The PCM also provides a means to
decelerate without disengaging speed control. To decelerate from an existing recorded target
speed, depress and hold the COAST switch until the desired speed is reached, then release the
switch.
The individual switches cannot be repaired. If one switch fails, the entire switch module must be
replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Cruise Control Switch >
Component Information > Diagrams > Page 553
Cruise Control Switch: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove
airbag/horn pad from steering wheel. 4. Disconnect wire connector from horn switch, airbag, and
speed control switches.
Speed Control Switches
5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control
switch from airbag/horn pad.
INSTALLATION
- Reverse the preceding operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle
Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle
Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 562
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss
of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Cruise Control > Vehicle Speed
Sensor/Transducer - Cruise Control > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss
of Cruise Control > Page 568
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Engine > Oil Pressure Sender > Component
Information > Locations
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Description and Operation
Air Conditioning Switch: Description and Operation
SYSTEM OPERATION
HVAC Mounted Switch
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Ambient Temperature Sensor /
Switch HVAC > Component Information > Service and Repair
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
1. Raise and support vehicle on safety stands. 2. From behind front bumper fascia, remove screw
holding sensor to radiator closure panel. 3. Remove sensor from vehicle.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Blower Motor Switch > Component
Information > Description and Operation
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
The rear blower speed switch controls the rear blower with the choice of low and high speeds.
When the switch is on it allows the blower speed switch located on the rear headliner to control
rear blower speed. This switch will override the rear headliner blower switch. For operation
instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from
the A/C control module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection
Evaporator Temperature Sensor / Switch: Testing and Inspection
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
- Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one's digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cool-down test is exited.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Evaporator Temperature Sensor /
Switch > Component Information > Testing and Inspection > Page 586
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
- For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
Refrigerant Pressure Sensor / Switch: Technical Service Bulletins Emissions, A/C, Cruise Control Manual Revisions
NUMBER: 26-03-98E
GROUP: Miscellaneous
DATE: March, 1998
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1998 2.4L/2.5L/3.0L/3.3L/3.8L - NS Powertrain Diagnostic Manual - Publication Number
81-699-97028
DESCRIPTION OF CHANGES
Revision to the Speed Control Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 591
76
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 592
78
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 593
80
Revision to the EGR System Failure Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 594
235
Revision to the A/C Pressure Sensor Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 595
292
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 596
296
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Page 597
A/C Pressure Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Page 598
A/C Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Fuel Gauge Sender >
Component Information > Locations > Page 603
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Instrument Panel > Outside Temperature
Display Sensor > Component Information > Locations > Page 607
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 612
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 613
Brake Light Switch: Service Precautions
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 614
Brake Light Switch: Description and Operation
The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped
with speed control, the stop lamp switch will deactivate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and
Center High Mount Stop Lamp (CHMSL) lamp, by supplying battery current to these lamps.
The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the
stop lamps.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 615
Brake Light Switch: Adjustments
1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise
direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch
firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until
it has ratcheted out to
its fully extended position.
4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting bracket. When switch is fully installed in the
square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the
bracket.
Stop Light Switch Location In Vehicle
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake
pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the
correct position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 616
Brake Light Switch: Service and Repair
REMOVAL
Stop Lamp Switch
1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise
direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3.
Disconnect wiring harness connector from stop lamp switch.
INSTALLATION
NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of
the stop lamp switch until it has ratcheted out to
its fully extended position.
2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch
into the bracket using the following procedure. Depress the brake pedal as far down as possible.
Then install switch in
bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When
switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into
bracket.
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If to much force is used, damage to the stop lamp switch or striker can result.
4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger
to ratchet backward to the correct position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 625
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 626
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 627
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 628
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 629
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 630
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 636
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 637
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 638
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 639
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 640
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 641
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch
> Component Information > Service and Repair
Glove Box Lamp Switch: Service and Repair
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Glove Box Lamp And Switch
3. Disengage wire connector from glove box lamp and switch. 4. Remove glove box lamp and
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Hazard Warning Switch
> Component Information > Service and Repair
Hazard Warning Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Dimmer
Switch > Component Information > Description and Operation
Headlamp Dimmer Switch: Description and Operation
GENERAL INFORMATION
The headlamp dimmer switch is incorporated into the multi-function (turn signal) switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams
Headlamp Switch: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 654
Headlamp Switch: Testing and Inspection
Headlamp Switch Test
Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test.
Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within
specifications replace as necessary.
The Chrysler Town and Country is available with optional Automatic Headlamps.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch
Headlamp Switch: Service and Repair Headlight Switch
Headlamp Switch
REMOVAL
1. Remove instrument cluster bezel. 2. Remove screws holding the headlamp switch bezel to
cluster bezel. 3. Disconnect the wire connectors from the headlamp switch and wire connector from
the power mirror switch. 4. Remove headlamp switch bezel from cluster bezel.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch > Page 657
Headlamp Switch: Service and Repair Headlight Switch Lamp
Headlamp Switch Lamp
REMOVAL
1. Remove instrument cluster bezel. 2. Disconnect wire connectors. 3. Remove headlamp switch
bezel from instrument cluster bezel. 4. Rotate bulb socket counter clockwise one quarter turn. 5.
Pull bulb socket from headlamp switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Horn Switch >
Component Information > Service and Repair
Horn Switch: Service and Repair
The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Locations > Page 664
Interior Light Switch: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Locations > Page 665
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Multi-Function Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 669
Turn Signal Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 670
Turn Signal Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and
Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 680
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
681
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 684
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 685
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 686
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 687
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 688
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 689
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 690
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 691
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 692
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 693
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 694
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 695
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 696
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 697
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 698
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 699
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 700
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 701
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 702
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 703
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 704
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 705
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 706
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 707
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 708
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 712
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 713
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 714
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 715
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 716
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 720
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 723
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 724
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 725
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 726
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 727
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 728
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 729
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 730
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 731
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 732
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 733
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 734
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 735
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 736
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 737
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 738
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 739
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 740
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 741
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 742
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
743
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
744
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
745
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
746
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Tank Sending Unit Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 753
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 754
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 755
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 756
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
MAP Sensor ........................................................................................................................................
.......................................................... 4 Nm (35 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 760
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 761
Map Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 762
Manifold Pressure/Vacuum Sensor: Description and Operation
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 763
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Fig 92 Map Sensor Connector
NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and
appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3
(Fig. 92). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a
hot, neutral idle speed condition. If OK, go to next step.
- If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition.
- Repair as required.
3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43.
- If OK, go to next step.
- If not OK, repair as required.
4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON.
The voltage should be approximately 5 volts (4.5
to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor.
- If not OK, repair or replace the wire harness as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 764
Manifold Pressure/Vacuum Sensor: Service and Repair
Fig 9 MAP Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake
manifold (Fig. 9). 3. Remove sensor from manifold.
INSTALLATION
- Reverse the above procedure for installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical
Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical
Specifications > Page 769
Oxygen Sensor: Mechanical Specifications
Upstream 02S ......................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Downstream 02S .................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations
Oxygen Sensor: Component Locations
Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling
and Exhaust/Engine/Tune-up and Engine
Performance Checks/Firing Order/Specifications
- If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered
O2 Sensor 1/2, even if it uses two upstream
HO2S.
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 772
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 773
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen
Sensor Connector
Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen
Sensor Connector > Page 776
Downstream Heated Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 777
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Engine, Cooling
and Exhaust/Engine/Tune-up and Engine
Performance Checks/Firing Order/Specifications
- If a V-6 or V-8 vehicle only uses one downstream Heated Oxygen Sensor (HO2S) it is numbered
O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 778
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 781
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 782
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground.
- The white wires in the sensor connector are the power and ground circuits for the heater.
- Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor
connector.
3. Resistance should be between 4 and 7 ohms.
- If not replace the sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
Fig 122 Oxygen Sensor Grommet Cover
WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen
sensor.
REMOVAL
1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122).
Fig 123 Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123).
Fig 124 Oxygen Sensor Removal & Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the
sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If
using original sensor, coat the threads
with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement > Page 785
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement > Page 786
Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Fig 121 Upstream Heated Oxygen Sensor
The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121).
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when
servicing the oxygen sensor.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 791
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 792
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 793
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 794
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 795
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 796
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 805
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 806
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 807
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 813
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 814
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 819
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 820
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 821
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 08-45-99 > Dec > 99 >
Radio - Poor AM Reception/Ignition Noise
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 08-45-99 > Dec > 99 >
Radio - Poor AM Reception/Ignition Noise > Page 827
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 08-45-99 > Dec > 99 >
Radio - Poor AM Reception/Ignition Noise > Page 828
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 831
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 832
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 833
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 834
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 835
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 836
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 842
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 843
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 844
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 845
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 846
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 847
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 848
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 849
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 850
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 851
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 852
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 853
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 854
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 855
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 856
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 857
Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 858
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 859
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Circuit Operation
Vehicle Speed Sensor: Description and Operation Circuit Operation
CIRCUIT OPERATION
If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM)
transmits the vehicle speed signal to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Circuit Operation > Page 862
Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM
NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor.
CIRCUIT OPERATION
The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that
information to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Circuit Operation > Page 863
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation
Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical
OPERATION
The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM.
The speed and distance signals, along with a closed throttle signal from the TPS, determine if a
closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired
MAP value.
- Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine
speed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Page 864
Vehicle Speed Sensor: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain
Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also
refer to the DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
869
Fuel Low Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 873
Fuel Temperature Sensor Connector CNG
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 878
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 879
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 880
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 881
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 882
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 883
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 889
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 890
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 893
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 894
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 895
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 896
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 897
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 898
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 899
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 900
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 901
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 902
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 903
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 904
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 905
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 906
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 907
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 908
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 909
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 910
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 911
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 912
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 913
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 914
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 915
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 916
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 917
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 921
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 924
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 925
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 926
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 927
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 928
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 929
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 930
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 931
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 932
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 933
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 934
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 935
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 936
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 937
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 938
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 939
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 940
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 941
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 942
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 943
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 944
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 945
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 946
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 947
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed > Page 957
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed > Page 963
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 964
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 965
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 969
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 970
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 971
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 972
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 978
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 979
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 980
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 981
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 982
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 983
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 984
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT: Airbag On-Off Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED
SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 985
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 986
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 987
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 988
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 989
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Air Bag Deactivation
Switch > Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 990
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Testing and Inspection
Impact Sensor: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Battery Temperature
Sensor > Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 1007
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page
1013
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1014
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 1015
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > Page 1019
Connector Pin Identification
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Range Sensor (TRS) Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1025
Transmission Mode Switch: Description and Operation
PARK/NEUTRAL POSITION SWITCH INPUT (ATX)
Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to
the Powertrain Control Module (PCM) on gearshift position.
Circuit T41 connects to cavity 76 of the PCM.
TRANSMISSION RANGE SENSOR (TRS)
The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor
provides the Transmission Control Module (TCM) with information on shift lever position, contains
the transmission temperature sensor, and contains the switch for the back-up lamps.
Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the
NEUTRAL/OVERDRIVE or LOW position.
Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position.
Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE,
NEUTRAL, or LOW position.
Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL
position. This circuit is also the ground circuit for the coil side of the engine starter motor relay.
The TRS is case grounded to the transmission.
Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the
RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block.
When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1
circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive
(AWD) solenoids, if equipped.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1026
Transmission Mode Switch: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
12. Remove TRS retaining screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 1027
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1036
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1037
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1038
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor
- Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor
- Production Change > Page 1044
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor
- Production Change > Page 1045
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement > Page 1050
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement > Page 1051
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed
Gear Engagement > Page 1052
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 1058
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All
Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 1059
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly > Page 1062
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid
and Pressure Switch Assembly > Page 1063
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1064
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1065
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1066
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 1067
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1076
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1081
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1082
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1083
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Component
Information > Service and Repair
Headlamp Bulb: Service and Repair
Headlamp Bulb
REMOVAL
1. Release hood latch and open hood. 2. From behind radiator closure panel, disengage wire
connector from back of headlamp bulb base. 3. Rotate headlamp bulb retaining ring counter
clockwise. 4. Disengage retaining ring from headlamp. 5. Pull headlamp bulb from back of
headlamp.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
1. From behind radiator closure panel, insert headlamp bulb into back of headlamp. 2. Engage
retaining ring onto headlamp. 3. Rotate headlamp bulb retaining ring clockwise. 4. Engage wire
connector into headlamp bulb base. 5. Verify headlamp alignment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed
Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed
Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 1095
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed
Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed
Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1100
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed
Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1101
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Other
Service Bulletins for Transmission Speed Sensor: > 02-09-97A > Oct > 97 > Customer Interest for Transmission Speed
Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 1102
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control > Page 1110
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 1115
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 1116
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 1117
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension Thumping Noise
Suspension Travel Bumper: All Technical Service Bulletins Rear Suspension - Thumping Noise
NO: 02-09-97 Rev. A
GROUP: Suspension
DATE: Oct. 24, 1997
SUBJECT:
Thumping Noise At Rear Of Vehicle During Cold Operations
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-09-97 WHICH SHOULD
BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
AND INCLUDES A CLARIFICATION OF AFFECTED MODELS AND PARTS REQUIRED.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SUSPENSION SALES CODE SDB
OR ALL WHEEL DRIVE (AWD).**
SYMPTOM/CONDITION:
Thumping noise from the rear jounce bumpers when driving over small bumps after the vehicle has
been in very cold temperatures (below 100 F.) for three hours or longer.
DIAGNOSIS:
After the vehicle has been exposed to temperatures of 100 F. (-12° C.) or below, load the vehicle
so the rear jounce bumpers are 1/2 in. (13 mm) away from the rear axle. Drive the vehicle over
small bumps and listen for a thumping noise. The condition should improve if the temperature
increases or the after the vehicle has been driven a few miles. If the thumping noise is heard,
perform the Repair Procedure.
PARTS REQUIRED:
AR (2) 04684756AB Bumper, Jounce Front Wheel Drive (FWD)
AR (2) 04684758AB Bumper, Jounce All Wheel Drive (AWD)
**NOTE:
DO NOT INSTALL JOUNCE BUMPERS MADE OF URETHANE (NOT BLACK) ON VEHICLES
ORIGINALLY EQUIPPED WITH RUBBER (BLACK) JOUNCE BUMPERS.**
REPAIR PROCEDURE:
This bulletin involves replacing the rear axle jounce bumpers.
1. Using slip-joint pliers, grasp the base of the jounce bumper and turn counter-clockwise.
2. Separate the jounce bumper from the vehicle and discard.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A > Oct > 97 > Rear Suspension Thumping Noise > Page 1123
3. Install the appropriate revised jounce bumper specified in Parts Required.
4. Repeat steps 1 through 3 for the other side jounce bumper.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 02-30-04-90 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Technical Service
Bulletins > Page 1124
Suspension Travel Bumper: Specifications
To Frame Rail ......................................................................................................................................
............................................... 33 Nm (290 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Service and
Repair > Standard
Suspension Travel Bumper: Service and Repair Standard
NOTES:
- There are two types of jounce bumpers available depending on which suspension option the
vehicle is equipped with.
- The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a
weld nut located on the frame rail.
REMOVAL
1. Using the proper tool, remove the bolt attaching the jounce bumper to frame rail. 2. Remove the
jounce bumper from the frame rail.
INSTALLATION
1. For installation, reverse the removal procedure. Tighten the jounce bumper mounting bolt to a
torque of 33 Nm (290 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Service and
Repair > Standard > Page 1127
Suspension Travel Bumper: Service and Repair Heavy Duty
NOTES:
- There are two types of jounce bumpers available depending on which suspension option the
vehicle is equipped with.
- The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a
weld nut located on the frame rail.
REMOVAL
1. Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise. 2.
Remove the jounce bumper from the frame rail.
INSTALLATION
1. For installation, reverse the removal procedure. Tighten the jounce bumper to a torque of 33 Nm
(290 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Locations >
Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Locations >
Compressed Natural Gas > Page 1131
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Component Information > Page 1132
Suspension Travel Bumper: Specifications
To Frame Rail ......................................................................................................................................
............................................... 33 Nm (290 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information >
Testing and Inspection
Evaporator Temperature Sensor / Switch: Testing and Inspection
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
- Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one's digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cool-down test is exited.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information >
Testing and Inspection > Page 1136
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
- For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information >
Locations
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Component Information >
Locations > Page 1139
Transmission Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1145
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1146
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1147
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1148
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1149
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1150
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1151
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1152
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1153
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1154
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1155
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1156
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1157
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1158
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1159
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1160
Transmission Temperature Sensor/Switch: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1161
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1162
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 1163
Transmission Control System (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation >
Transmission Range Sensor
Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation >
Transmission Range Sensor > Page 1166
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Description and Operation
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation >
Transmission Range Sensor > Page 1167
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation >
Transmission Range Sensor > Page 1168
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Circuit Operation
CIRCUIT OPERATION
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The
T54 circuit connects to cavity 54 of the TCM connector.
Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and
output speed sensor. This circuit connects to cavity 13 of the TCM connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Transmission and Drivetrain > Sensors and
Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation >
Page 1169
Transmission Temperature Sensor/Switch: Testing and Inspection
Chrysler does not provide a procedure to test the transmission temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection
Power Window Switch: Testing and Inspection
Power Window and Vent Switch Test
1. Remove the driver or passenger door power window switch and bezel assembly from door trim
panel.
Power Window Master Switch Connector
Driver Door Power Window Switch Test
2. Using an ohmmeter, Test driver door switch for continuity.
* MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN
PINS 11 AND 6
Passenger Door Power Window Switch
3. Test passenger door switch for continuity.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Windows and Glass > Power Window Switch
> Component Information > Testing and Inspection > Page 1174
4. If the results are not OK, replace the switch.
The driver door power window switch has a Auto-Down feature. The switch is equipped with two
detent positions when actuating the power window OPEN. The first detent position allows the
window to roll down and stop when the switch is released. The second detent position actuates an
integral express roll down relay that rolls the window down after the switch is released. When the
express down relay senses an amperage spike (motor pushing against down stop) in the feed
circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the
switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an
amperage spike will cause the switch to disconnect after approximately 11 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Washer Fluid
Level Switch > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection
Windshield Washer Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch.
Windshield Wiper And Washer - Multi Function Switch Test
2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers.
Switch Position = Resistance Value Between
OFF = 6 AND 7 - MAX 1.0 Ohms
Delay Position
1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6
AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256
Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5
Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Windshield
Washer Switch > Component Information > Testing and Inspection > Page 1182
Windshield Washer Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Turn Signal Multi-Function Switch
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove
screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection
Wiper Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch.
Windshield Wiper And Washer - Multi Function Switch Test
2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers.
Switch Position = Resistance Value Between
OFF = 6 AND 7 - MAX 1.0 Ohms
Delay Position
1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6
AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256
Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5
Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Sensors and Switches > Sensors and Switches - Wiper and Washer Systems > Wiper Switch
> Component Information > Testing and Inspection > Page 1186
Wiper Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Turn Signal Multi-Function Switch
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove
screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative
Fuels or Electric Engine
Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine
FRONT:
Individual Camber [1] ...........................................................................................................................
..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed
................................................................................................................................... 0.00° - 0.50°
MAX Individual Caster [2] ....................................................................................................................
............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to
Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ...................................................................................................
........................................................................ +0.05° ± 0.10° Total Toe ............................................
........................................................................................................................................................
+0.10° ± 0.20° Side to Side Toe Differential ........................................................................................
....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle ....................
..............................................................................................................................................................
. 0.00° ± 2.50° Ride Height [7] .............................................................................................................
................................................................... 783.5 mm ± 10.0 mm Ride Height Side to Side
Differential ...........................................................................................................................................
0.0 mm 12.5 mm MAX
REAR:
Individual Camber ................................................................................................................................
...................................................... +0.00° ± 0.25° Individual Toe Right/Left .......................................
...................................................................................................................................... 0.00° ± 0.40°
Total Toe [4, 6] ....................................................................................................................................
......................................................... 0.00° ± 0.40° Thrust Angle [4] ...................................................
........................................................................................................................................ 0.00° ± 0.30°
Ride Height [5, 7] .................................................................................................................................
........................................... 802.5 mm ± 10.0 mm Ride Height Side to Side Differential [5]
...................................................................................................................................... 0.0 mm 12.5
mm MAX
[1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent.
[2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
[3]: Toe-In is positive.
[4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
[5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the
vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the
ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are
not adjustable. If found to be out of specification check for damaged and/or worn out suspension
components and replace as necessary.
[6]: Toe out when backed on alignment rack is toe in when driving.
[7]: Measured at top of fender wheel opening.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative
Fuels or Electric Engine > Page 1192
Alignment: Specifications With Tire Sizes P205/75/R14 or P215/65/R15
FRONT:
Individual Camber [1] ...........................................................................................................................
..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed
................................................................................................................................... 0.00° - 0.50°
MAX Individual Caster [2] ....................................................................................................................
............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to
Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ...................................................................................................
........................................................................ +0.05° ± 0.10° Total Toe ............................................
........................................................................................................................................................
+0.10° ± 0.20° Side to Side Toe Differential ........................................................................................
....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle ....................
..............................................................................................................................................................
. 0.00° ± 2.50° Ride Height [7] .............................................................................................................
................................................................... 747.5 mm ± 10.0 mm Ride Height Side to Side
Differential ...........................................................................................................................................
0.0 mm 12.5 mm MAX
REAR:
Individual Camber ................................................................................................................................
...................................................... +0.00° ± 0.25° Individual Toe Right/Left .......................................
...................................................................................................................................... 0.00° ± 0.40°
Total Toe [4, 6] ....................................................................................................................................
......................................................... 0.00° ± 0.40° Thrust Angle [4] ...................................................
........................................................................................................................................ 0.00° ± 0.30°
Ride Height [5, 7] .................................................................................................................................
........................................... 766.0 mm ± 10.0 mm Ride Height Side to Side Differential [5]
...................................................................................................................................... 0.0 mm 12.5
mm MAX
[1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent.
[2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
[3]: Toe-In is positive.
[4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
[5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the
vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the
ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are
not adjustable. If found to be out of specification check for damaged and/or worn out suspension
components and replace as necessary.
[6]: Toe out when backed on alignment rack is toe in when driving.
[7]: Measured at top of fender wheel opening.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Vehicles Using Alternative
Fuels or Electric Engine > Page 1193
Alignment: Specifications With Tire Sizes P205/75/R15 or P215/65/R16
FRONT:
Individual Camber [1] ...........................................................................................................................
..................................................... +0.05° ± 0.40° Camber Side to Side Difference Not to Exceed
................................................................................................................................... 0.00° - 0.50°
MAX Individual Caster [2] ....................................................................................................................
............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to
Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ...................................................................................................
........................................................................ +0.05° ± 0.10° Total Toe ............................................
........................................................................................................................................................
+0.10° ± 0.20° Side to Side Toe Differential ........................................................................................
....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle ....................
..............................................................................................................................................................
. 0.00° ± 2.50° Ride Height [7] .............................................................................................................
................................................................... 753.5 mm ± 10.0 mm Ride Height Side to Side
Differential ...........................................................................................................................................
0.0 mm 12.5 mm MAX
REAR:
Individual Camber ................................................................................................................................
...................................................... +0.00° ± 0.25° Individual Toe Right/Left .......................................
...................................................................................................................................... 0.00° ± 0.40°
Total Toe [4, 6] ....................................................................................................................................
......................................................... 0.00° ± 0.40° Thrust Angle [4] ...................................................
........................................................................................................................................ 0.00° ± 0.30°
Ride Height [5, 7] .................................................................................................................................
........................................... 772.0 mm ± 10.0 mm Ride Height Side to Side Differential [5]
...................................................................................................................................... 0.0 mm 12.5
mm MAX
[1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent.
[2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
[3]: Toe-In is positive.
[4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
[5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the
vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the
ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are
not adjustable. If found to be out of specification check for damaged and/or worn out suspension
components and replace as necessary.
[6]: Toe out when backed on alignment rack is toe in when driving.
[7]: Measured at top of fender wheel opening.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Specifications > Page 1194
Alignment: Service Precautions
CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle
alignment specifications, by heating and or bending.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Front-End
Alignment
Alignment: Description and Operation Front-End Alignment
GENERAL INFORMATION
Wheel alignment is the proper adjustment of all the interrelated suspension angles affecting the
running and steering of the front and rear wheels of the vehicle. The method of checking front and
rear wheel alignment will vary depending on the type of equipment being used. The instructions
furnished by the manufacturer of the equipment should always be followed. With the exception that
the wheel alignment specifications recommended by Chrysler Corporation should always be used.
DESCRIPTION
There are six basic factors which are the foundation to front wheel alignment. These are vehicle
height, caster, camber, toe-in, steering axis inclination and toe-out on turns. Of the six basic factors
only toe-in is normally mechanically adjustable on this vehicle.
Camber Adjustment - is allowed in the event that a vehicle is involved in an accident and after
repairs are made meeting manufacturers tolerance specifications, the camber setting will not meet
manufacturers specifications. If camber adjustment is required, refer to the following Service
Camber Adjustment Procedure for the required steps to be followed.
CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle
alignment specifications, by heating and or bending.
CHECKS AND ADJUSTMENTS
Alignment checks and adjustments should be made in the following sequence: 1. Camber 2. Toe
Camber - is the number of degrees the top of the wheel and tire assembly is tilted inboard or
outboard from a true vertical line. Inboard tilt is negative camber. Outboard tilt is positive camber.
Excessive camber is a tire wear factor: negative camber causes wear on the inside of the tires
tread surface, while positive camber causes wear to the outside of the tires tread surface.
Toe - is measured in degrees or inches and is the distance the front edges of the tires are closer
(or farther apart) than the rear edges.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Front-End
Alignment > Page 1197
Alignment: Description and Operation Rear
Alignment adjustment is not required. The rear axle alignment settings are preset at the factory and
therefore no alignment is necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Description and Operation > Page 1198
Alignment: Testing and Inspection
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct the wheel alignment factors. The following part
inspection and the necessary corrections should be made to those parts which influence the
steering of the vehicle. 1. Check and inflate all tires to recommended pressure. All tires should be
the same size and in good condition and have approximately the same
wear. Note the type of tread wear which will aid in diagnosing, refer to Tires.
2. Check front wheel and tire assembly for radial runout. 3. Inspect lower ball joints and all steering
linkage for looseness. 4. Check for broken or sagged front and rear springs. 5. Check vehicle ride
height to verify it is within specifications. 6. Alignment MUST only be checked after the vehicle has
the following areas inspected and or adjusted. Recommended tire pressures, full tank
of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated
alignment rack.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and
Camber
Alignment: Service and Repair Checking Caster and Camber
NOTE: All alignment specifications are to be checked and adjusted with the vehicle at its correct
ride height.
GENERAL INFORMATION
Front suspension Caster and Camber settings on this vehicle are determined at the time the
vehicle is designed. This is done by determining the precise mounting location of the vehicle's
suspension components throughout the design and assembly processes of the vehicle. This is
called a Net Build vehicle and results in no normal requirement to adjustment the Caster and
Camber after a vehicle is built or when servicing the suspension components. Thus Caster and
Camber are not normally considered an adjustable specification when performing an alignment on
this vehicle. Though Caster and Camber are not adjustable they should be checked during the
alignment procedure to ensure they meet the manufacturers specifications.
PROCEDURE
If front camber does not meet the vehicle alignment specifications, it can be adjusted using a
Mopar (R) Service Kit, or equivalent developed to allow for camber adjustment. If a vehicle's front
camber does not meet required specifications, the vehicles suspension components should be
inspected for any signs of damage or bending and the vehicle ride height should be checked to
verify it is within required specification. This inspection must be done before using the Mopar (R)
Service Kit for setting camber to the vehicle specification.
CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating bending or by
performing any other modification to the vehicle's front suspension components.
1. Correctly position the vehicle on the alignment rack. Then install all required alignment
equipment on the vehicle, per the alignment equipment
manufacturers specifications.
NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an
equal number of times. Induce jounce (rear first then front) by grasping center of bumper and
jouncing each end of vehicle an equal number of times. Bumper should always be released when
vehicle is at the bottom of the jounce cycle.
2. Correctly jounce vehicle and then read the vehicle's current front and rear alignment settings.
Compare the vehicle's current alignment settings
to the vehicle specifications for camber, caster and Toe-in. If front and rear camber readings are within required specifications proceed to Setting Front Toe for
the Toe-in adjustment procedure if required. See: Front Alignment
- If Camber readings are not within specifications refer to Setting Camber Adjustment and Cam Bolt
Installation. See: Setting Camber Adjustment and Cam Bolt Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and
Camber > Page 1201
Alignment: Service and Repair Front Alignment
1. Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. 2. Center
steering wheel and lock in place using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe
adjustment.
3. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate
inner tie rods of steering gear to set front Toe to the
preferred Toe specification.
4. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 5. Adjust steering gear to tie rod boots at tie
rod. 6. Remove steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and
Camber > Page 1202
Alignment: Service and Repair Setting Camber Adjustment and Cam Bolt Installation
1. If the front camber readings obtained are not within the vehicle's specifications, use the following
procedure and the Mopar (R) Clevis Bolt
Service Kit, or equivalent to provide camber adjustment. The kit contains 2 flange bolts, 2 cam
bolts, and 2 dog bone washers. These components of the service kit are necessary to assemble
the strut to the steering knuckle, after modification of the strut clevis bracket.
2. Verify that the strut and steering knuckle are not bent or otherwise damaged. If either component
is bent or show other signs of damage, replace
required components and check the camber setting again.
3. If no component is bent or damaged, use the following procedure for modifying the strut clevis
bracket and adjusting the camber setting. 4. Raise front of vehicle until tires are not supporting the
weight of the vehicle. Then remove wheel and tire assembly from the location on the
vehicle requiring the strut to be modified.
CAUTIONS: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake
flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake
flex hose when removed from the strut assembly. If necessary use a wire hanger to support the
steering knuckle assembly or if required remove the brake flex hose from the caliper assembly.
- The steering knuckle strut assembly attaching bolts are serrated and must not be turned during
removal. Remove nuts while holding bolts stationary in the steering knuckles.
5. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard.
Separate the steering knuckle from the Strut clevis
bracket and position steering knuckle so it is out of the way of the strut.
CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the
hole beyond the indentations on the sides of the strut clevis bracket.
6. Using an appropriate grinder and grinding wheel slot the bottom hole in both sides of the strut
clevis bracket. When grinding slot do not go beyond
the indentation area on the sides of the clevis bracket.
CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog
bone washers from the Mopar (R) Clevis Bolt Service Kit, or equivalent can be used to attach the
steering knuckle to the strut after the mounting hole is slotted.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Alignment > System Information > Service and Repair > Checking Caster and
Camber > Page 1203
7. Install the flanged bolt from the Mopar (R) Clevis Bolt Service Kit, or equivalent into the top clevis
bracket to steering knuckle mounting hole.
Install the cam bolt into the bottom clevis bracket to steering knuckle mounting hole.
8. Install the dog bone washer on the steering knuckle to strut clevis bracket attaching bolts. Then
install the nuts from the original attaching bolts
onto the replacement bolts from the service kit. Tighten the bolts just enough to hold the steering
knuckle in position when adjusting camber, while still allowing the steering knuckle to move in
clevis bracket.
9. Lower vehicle until the full weight of the vehicle is supported by the vehicles' suspension. Then
correctly jounce the front and rear of vehicle an
equal amount of times.
10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket.
When camber is correctly set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again
jounce front and rear of vehicle an equal amount of times and verify front camber setting.
11. When vehicle is at correct camber setting torque both front strut to steering knuckle attaching
bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4
turn after required torque is met.
12. If Toe readings obtained are not within the required specification range, adjust Toe to meet the
preferred specification setting.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations > Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations > Compressed Natural Gas > Page 1210
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air/Fuel Mixture > System
Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 1217
Idle Speed: Testing and Inspection
THROTTLE BODY MINIMUM AIR FLOW CHECK
Fig 97 Air Metering Fitting 6457
Fig 100 PCV Valve
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the
intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457
(0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from
the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link
connector.
10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The
following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
airflow is set correctly.
2.4L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 500-875 RPM
Above 1000 Miles 550-875 RPM
3.0L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 560-910 RPM
Above 1000 Miles 610-910 RPM
3.3L/3.8L Idle Specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Idle Speed > System Information
> Specifications > Page 1218
Odometer Reading Idle RPM
Below 1000 Miles 525-875 RPM
Above 1000 Miles 575-875 RPM
14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let
Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash
thoroughly after using cleaner.
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle
purge line. 18. Remove DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Fig 125 Air Inlet Resonator
REMOVAL
1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner
housing halves together.
Fig 126 Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing (Fig. 126).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 1223
Fig 127 Air Cleaner Element
4. Remove element from air cleaner housing (Fig. 127).
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > CNG Engine > Page 1229
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Firing Order > Component
Information > Specifications
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Number One
Cylinder > Component Information > Locations
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Timing > Timing Marks
and Indicators > System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications
Ignition Cable: Specifications
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Specifications > Page 1243
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
PURPOSE
Transfer electrical current from the coil to the individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
CONSTRUCTION
The spark plug cables and spark plug boots are made from high temperature silicone materials.
Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust
manifold. The heat shields slide over the spark plug boots.
- The notches on the heat shields ensure the spark plug boot and shield twist together during spark
plug boot removal.
- They also identify proper heat shield installation on the boot for service.
- All spark plug cable leads are properly identified with cylinder numbers.
Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure.
- Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent
or missing.
- Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems.
- The bottom of the spark plug heat shield must make contact with the spark plug hex.
Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone
grease for greater sealing and to minimize boot bonding to the spark plug insulator.
The convoluted tubing on the rear plug cables are made of a high temperature plastic material.
Service Life Under normal driving conditions, the spark plug cables have a recommended service
life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for
severe driving conditions.
CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable
must not touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1246
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter.
- Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
INSPECTION
Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good
condition.
Covers should fit tightly on the coil pack and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
Secondary Ignition Cable Resistance Test
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service and Repair > Replacing Cables
Ignition Cable: Service and Repair Replacing Cables
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
- Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
- Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can
damage the ignition cable conductor.
SPARK PLUG CABLES #3 AND #5
Removal
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug.
- Twist the boot slightly to break its seal with the plug and pull straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the
retaining bracket.
- Make sure that they are also detached from the rear retaining clip mounted on the rear of the
intake manifold.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
SPARK PLUG CABLE #1
Removal
1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the
upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug
boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal
with the plug and pull
straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
5. Wipe spark plug insulator clean with a dry cloth before installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service and Repair > Replacing Cables > Page 1249
6. Remove the cable from the retaining bracket.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt, refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Ignition Cable > Component
Information > Service and Repair > Replacing Cables > Page 1250
Ignition Cable: Service and Repair Cleaning Cables
Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables
dry. Check for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1254
Spark Plug: Service Precautions
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1255
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Specifications > Page 1256
Spark Plug: Description and Operation
Fig 3 Platinum Plug Pads
NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal driving conditions. The recommended
service life under severe conditions is 75,000 miles.
- A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3).
- Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator
damage during plug removal and installation.
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator.
CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs.
This would damage the platinum pads which would shorten spark plug life.
Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's
original spark plugs that have been determined good. -
Do not apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-seize compound does not make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark
plugs without reading the procedures.
Due to the engine packaging environment for this engine, extreme care should be used when
installing the spark plugs to avoid cross threading problems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1259
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1260
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1261
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1262
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1263
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1264
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1265
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: -
In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Page 1266
Spark Plug: Adjustments
Setting Spark Plug Gap - Typical
Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or
oil fouled.
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Page 1267
Spark Plug: Service and Repair
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- Use extreme care when removing and installing the spark plug cables.
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
SPARK PLUG #3 AND #5
REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head.
3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield
assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break
the seal with the
plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
SPARK PLUG #1
REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts
from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark
plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly
slightly to break its seal with the
plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Spark Plug > Component
Information > Testing and Inspection > Page 1268
insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before
installation.
5. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure the coil or spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt, refer to Cooling System.
OTHER PLUGS
REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering
combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while
pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR: Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle
operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this
will allow deposit shifting in the combustion chamber to take place gradually and avoid plug
destroying splash fouling shortly after the plug change.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications
Compression Check: Specifications
Compression Ratio ..............................................................................................................................
........................................................................... 8.9:1 Minimum Compression ...................................
........................................................................................................................................ 689.5 kPa
(100 psi) Maximum Variation Between Cylinders ................................................................................
......................................................................................... 25%
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Compression Check > System
Information > Specifications > Page 1272
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. Ensure the battery is completely charged and the engine starter motor is in good
operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis
purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System (DIS) disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to
specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and
secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and
different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and
Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt
drives. 18. Road test vehicle as a final test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Tune-up and Engine Performance Checks > Valve Clearance > System
Information > Specifications
Valve Clearance: Specifications
This engine is equipped with hydraulic valve lifters and are not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage
Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1284
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1289
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1290
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Customer
Interest for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1291
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage
Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1297
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page
1302
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page
1303
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Drive Belt: > 07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page
1304
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1305
Drive Belt: Specifications
Belt Tension Chart
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1306
Drive Belt: Description and Operation
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and
the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump
and water pump. Satisfactory performance of these belts depends on belt condition and proper belt
tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool
C-4162. Because of space limitations in the engine compartment, the use of the gauge may be
restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the
drive belts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1307
Accessory Drive Belt
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Technical Service Bulletins > Page 1308
Drive Belt: Adjustments
Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt
tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because
of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the
vehicle on a hoist and the remove the splash shield to gain access to the drive belts.
Use belt tensioning Special Tool Kit C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges
are not interchangeable.
- For conventional V-belts affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the
belt tension for New or Used belt as prescribed in the Belt Tension Chart.
- For a Poly-V belt affix the Poly-V Burroughs gauge to the belt and then apply specified tension to
the belt as prescribed in the Belt Tension Chart.
Belt Tension Chart
Adjust belt tension for a New or Used belt as prescribed in the Belt Tension Chart.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation
Drive Belt: Service and Repair Removal and Installation
A/C Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install.
Alternator Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation > Page 1311
3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install.
Power Steering Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install.
Water Pump Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
3. Release tension by rotating the tensioner clockwise.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation > Page 1312
4. Reverse above procedure to install.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Drive Belt > Component Information > Service and Repair > Removal and
Installation > Page 1313
Drive Belt: Service and Repair Cleaning and Inspection
Serpentine Drive Belt Wear Patterns
When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt
from rib to rib, are considered normal these are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal. Any belt with cracks running along the rib must
be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair
Air Filter Element: Service and Repair
Fig 125 Air Inlet Resonator
REMOVAL
1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner
housing halves together.
Fig 126 Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing (Fig. 126).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Air Cleaner Housing > Air Filter Element > Component Information >
Service and Repair > Page 1319
Fig 127 Air Cleaner Element
4. Remove element from air cleaner housing (Fig. 127).
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Crankcase Filter > Component Information > Description and
Operation
Crankcase Filter: Description and Operation
This engine uses filtered air to vent the crankcase. The filtered air is drawn through the resonator
assembly located between the air cleaner and throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Fluid Drain and Refill
Fluid Filter - A/T: Service and Repair Fluid Drain and Refill
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil
pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm
(165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602
through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and
service brakes applied, move selector lever momentarily to each
position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark.
CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil
(100°F). Upper holes for hot oil (180°F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the
dipstick fill tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Fluid Filter - A/T > Component Information > Service and Repair >
Fluid Drain and Refill > Page 1327
Fluid Filter - A/T: Service and Repair Fluid & Filter Change
When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic
Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the
time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a
clean, dry cloth.
If the transaxle is disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Fuel Filter > Fuel Pressure Release > System Information > Service
and Repair > CNG Engine > Page 1333
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications
Oil Filter: Specifications
Oil Filter Attaching Nipple ....................................................................................................................
................................................... 41 Nm (30 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Oil Filter, Engine > Component Information > Specifications > Page
1337
Oil Filter: Service and Repair
Oil Filter
CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install
tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is
reinforced by the base plate.
1. Using Tool C-4065, turn filter counterclockwise to remove from base. Properly discard filter. 2.
Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean
engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.).
Use filter wrench if necessary. 5. Start engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications
Refrigerant Filter: Specifications
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................... 150 ml (5.0 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Filters > Refrigerant Filter > Component Information > Specifications > Page
1341
Refrigerant Filter: Service and Repair
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
1. Recover A/C system refrigerant.
Filter Drier Assembly
2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan
module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator
crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location.
INSTALLATION
1. Before installation, replace both refrigerant line O-rings. Then reverse the above procedure.
Torque filter/drier mounting bolts to 45 in. lbs. +/- 10. 2. Evacuate and recharge system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Locations
Heater Hose: Locations
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Locations > Page 1346
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hoses
Heater Hose: Service and Repair Heater Hoses
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Drain engine cooling system.
Upper Heater Hose
Lower Heater Hose
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core in let or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hoses > Page 1349
Heater Hose: Service and Repair Underbody Plumbing
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Heater Hose > Component Information > Service and Repair > Heater
Hoses > Page 1350
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
For more information, refer to Heater core/ Service and Repair. See: Engine, Cooling and
Exhaust/Cooling System/Heater Core/Service and Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > A/C Suction/Discharge Line - Service
Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service
NUMBER: 24-14-99
GROUP: Heating & A/C
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED
JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Suction And/Or Discharge Line Service
MODELS:
1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or
near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are
torqued to 40 ft. lbs. (54 Nm).
The root cause of A/C suction and/or discharge line cracking at or near the compressor may be
related to the compressor being improperly secured to the engine. Excessive vibration may result if
the compressor attaching bolts are not properly torqued. This vibration will eventually crack the
aluminum tubing of the A/C lines and/or compressor mounting ears.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Page 1355
Hose/Line HVAC: Locations
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Page 1356
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Page 1357
Hose/Line HVAC: Description and Operation
SYSTEM OPERATION
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Technical Service
Bulletins > Page 1358
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is dean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement
REMOVAL
1. Recover A/C system refrigerant.
Compressor Discharge Line
2. Remove discharge line mounting nut at compressor.
Condenser Discharge Line
3. Remove discharge line at the top fitting on the condenser.
INSTALLATION
1. For installation, reverse the above procedures. Replace all O-rings. Torque discharge line at
condenser bolt to 180 in. lbs. +/- 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC
Control Calibration Diagnostic and Cool-down test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1361
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9.
Cover the openings to prevent contamination.
10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at
right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line
mounting plate at filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece
assembly
13. Remove the old O-rings.
INSTALLATION
- For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1362
Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve.
Suction Line At Compressor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1363
9. Remove suction line mounting nut at compressor.
10. Remove suction line mounting bracket. 11. Remove suction line.
INSTALLATION
- For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1364
Hose/Line HVAC: Service and Repair Refrigerant Line Replacement
Rear Air Conditioning Lines
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Hose/Line HVAC > Component Information > Service and Repair >
A/C Discharge Hose/Line Replacement > Page 1365
Rear Heater Hose Connection
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
For more information, refer to Housing Assembly HVAC/ Service and Repair. See: Heating and Air
Conditioning/Housing Assembly HVAC/Service and Repair
Rear Heater A/C Air Outlets
REMOVAL
- Separate barrel from bezel by pulling outward.
INSTALLATION
- For installation, push the outlet firmly into the opening until it locks into place.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1374
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1375
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1376
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1377
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1378
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 1379
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk
Noise At Low Speed
Technical Service Bulletin # 19-11-97 Date: 971205
Power Steering Line - Honk Noise At Low Speed
NO: 19-11-97
GROUP: Steering
EFFECTIVE DATE: Dec. 5, 1997
SUBJECT: "Honk" Noise During Parking Lot Maneuvers
FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN
SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR
VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE
BULLETIN 19-07-97.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR
3.8L ENGINE.
SYMPTOM/CONDITION:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
DIAGNOSIS:
The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it
may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise
can be reproduced during the diagnostic procedure. The noise may decrease in severity or
disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings,
replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic
procedure is performed, will temporarily eliminate the noise for approximately 200 miles.
Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly
move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform
the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering
wheel back toward the right, repeat several times. If the noise is heard, perform the Repair
Procedure.
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011 873AA Line, Power Steering Return
AR 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 19-50-17-90 0.4 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing revised power steering pressure and return lines.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk
Noise At Low Speed > Page 1384
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1.
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear, Figure 2.
Discard the line and screw clamp.
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting,
Figure 3.
9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2.
Remove and discard the power steering pressure line.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk
Noise At Low Speed > Page 1385
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line, Figure 4.
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line on to the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in.
lbs.) Figure 2.
18. POWER STEERING FLUID LEVEL ADJUSTMENT
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering Line - Honk
Noise At Low Speed > Page 1386
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
19. Verify correct steering operation and no fluid leaks.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1392
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1393
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1394
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1395
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1396
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-05-98 > Aug > 98 > Power Steering Honk Or Squeal Noise at Low Speed > Page 1397
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering
Line - Honk Noise At Low Speed
Technical Service Bulletin # 19-11-97 Date: 971205
Power Steering Line - Honk Noise At Low Speed
NO: 19-11-97
GROUP: Steering
EFFECTIVE DATE: Dec. 5, 1997
SUBJECT: "Honk" Noise During Parking Lot Maneuvers
FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN
SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR
VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE
BULLETIN 19-07-97.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR
3.8L ENGINE.
SYMPTOM/CONDITION:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
DIAGNOSIS:
The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it
may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise
can be reproduced during the diagnostic procedure. The noise may decrease in severity or
disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings,
replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic
procedure is performed, will temporarily eliminate the noise for approximately 200 miles.
Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly
move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform
the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering
wheel back toward the right, repeat several times. If the noise is heard, perform the Repair
Procedure.
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011 873AA Line, Power Steering Return
AR 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 19-50-17-90 0.4 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing revised power steering pressure and return lines.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering
Line - Honk Noise At Low Speed > Page 1402
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1.
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear, Figure 2.
Discard the line and screw clamp.
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting,
Figure 3.
9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2.
Remove and discard the power steering pressure line.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering
Line - Honk Noise At Low Speed > Page 1403
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line, Figure 4.
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line on to the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in.
lbs.) Figure 2.
18. POWER STEERING FLUID LEVEL ADJUSTMENT
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: > 19-11-97 > Dec > 97 > Power Steering
Line - Honk Noise At Low Speed > Page 1404
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
19. Verify correct steering operation and no fluid leaks.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Technical
Service Bulletins > Page 1405
Power Steering Line/Hose: Specifications
Hose Tube Nuts ...................................................................................................................................
..................................................... 34 Nm (25 ft. lbs.) Routing Bracket To Suspension Cradle
.................................................................................................................................................... 28
Nm (21 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump
Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump
REMOVE
1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump,
remove as much power steering fluid as possible from the power steering fluid reservoir.
Power Steering Fluid Hose Routing Clip
3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle
on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the
power steering fluid hose coming from the power steering fluid reservoir. Let the power steering
fluid drain
out of the reservoir and hose.
6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the
power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle.
Hose is removed from the top of the engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose
must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed
under the wiring harness and below the drip tube. This routing will prevent the power steering fluid
supply hose from coming in contact with the accessory drive belt.
1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down
to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir.
Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed
past bead on fluid reservoir fitting.
3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering
fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure
hose clamp is installed
past bead on pump fitting.
5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is
installed in a position to correctly align with stud in strut tower. 7. Install routing clip for power
steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper let
and let the fluid settle for at least two (2) minutes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1408
9. Start the engine and let run for a few seconds. Then turn the engine off.
10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after
running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the
steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if
necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the
engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the
vehicle to stand a few minutes and repeat the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1409
Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose
WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if
engine has been running.
CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch
hot exhaust manifold or catalyst.
NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses,
power steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel
tube connection. Remove the hose clamp from the
power steering fluid return hose. Remove power steering fluid return hose from steel tube and
allow power steering fluid to drain from pump.
5. Remove the power steering fluid pressure line from the power steering pump pressure fitting.
Drain excess power steering fluid from hose.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1410
6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle.
7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid
from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid
pressure hose.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump
pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering
fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power
steering pressure hose to the fittings on the power steering pump and steering gear. Route hose
avoiding tight bends or kinking.
Do not bend tube ends of the power steering hoses when installing.
4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid
hoses must remain away from the exhaust system
and must not come in contact with any unfriendly surfaces of the vehicle.
CAUTION: When tightening and torquing the pressure hose at the power steering pump, the
pressure hose is to be rotated against the fluid return hose fitting on the pump.
5. Tighten all fasteners shown for specific applications to their correct torques listed below:
- Pump End Tube Nut: 34 Nm (25 ft. lbs.)
- Gear End Tube Nut: 34 Nm (25 ft. lbs.)
- Pump Bracket Nut: 40 Nm (30 ft. lbs.)
6. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 7.
Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1411
CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses.
8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
9. After hoses are installed and power steering system is filled with fluid and cap is installed on
reservoir. Start the engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Power Steering Line/Hose > Component Information > Service and
Repair > Supply Hose From Reservoir to Pump > Page 1412
Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose
WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if
engine has been running.
CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch
hot exhaust manifold or catalyst.
NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses,
power steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube
connection. Remove hose clamp where rubber portion
of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber
hose from steel tube and allow power steering fluid to drain from pump.
5. Remove the power steering fluid return hose from the power steering pump return hose fitting.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump
fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route
hose smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come in contact with any unfriendly surfaces of the
vehicle.
3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4.
Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is to prevent
overheating of the power steering fluid hoses.
5. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
6. After hoses are installed and power steering system is filled with fluid and caps installed on
reservoir. Start the engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Hoses > Radiator Hose > Component Information > Description and Operation
Radiator Hose: Description and Operation
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND
WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW
FLUIDS AND STEAM TO ESCAPE THROUGH THE OVERFLOW TUBE. THIS WILL RELIEVE
SYSTEM PRESSURE
The hoses are removed by using constant tension clamp pliers to compress the hose clamp. A
hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet
and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed
as designed. The use of molded hoses is recommended. Spring type hose clamps are used in all
applications. If replacement is necessary replace with the original Mopar (R) equipment spring type
clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Specification ........................................................................................................................................
.................................................................. DOT 3
Standard ..............................................................................................................................................
........................................................... SAE J1703
NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703
standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake
system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An
open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1420
Brake Fluid: Testing and Inspection
CAUTION:
The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic
fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid
absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the
vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake
fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an
equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid. This
includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS
hydraulic control unit (HCU), and all hydraulic fluid hoses.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Brake Fluid > Component Information > Specifications > Page 1421
Brake Fluid: Service and Repair
FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a minimum of twice annually.
Master Cylinder Fluid Level Marks
Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder.
If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the
master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of
the fluid reservoir with brake fluid.
Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to
DOT 3, specifications.
DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly sealed container.
DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would
be items such as engine oil, transmission fluid, power steering fluid ect.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications
Coolant: Capacity Specifications
COOLING SYSTEM CAPACITY
2.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 10.6 L (11.23 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.................................................................. N/A Rear Heater ...............................................................
............................................................................................................................................. N/A
3.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
........................................................................................................................ 15.0 L (15.9 qts)
3.3/3.8L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
Trailer Tow
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
NOTE: Capacities include heater and coolant recovery tank filled to Max level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Specifications > Capacity
Specifications > Page 1426
Coolant: Fluid Type Specifications
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a
minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided with a 68% antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used
Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the
corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F).
Propylene-Glycol Formulations Should Not Be Used
Propylene-glycol formulations do not meet the required specifications. It's overall effective
temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at
96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics
than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.
Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used
Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion
inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and
propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the
freeze point will not be accurate. Both the refractive index and specific gravity differ between the
ethylene-glycol and propylene-glycol.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
General Information
Coolant: Description and Operation General Information
The cooling system is designed around the coolant. The coolant must accept heat from engine
metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the
radiator, where the tube/fin assemblies of these components can give it up to the air. The use of
aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection.
Mopar (R) Antifreeze or the equivalent is recommended for best engine cooling without corrosion,
when mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it loses color or becomes
contaminated, drain, flush, and replace with fresh properly mixed solution.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation >
General Information > Page 1429
Coolant: Description and Operation
Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for
each degree of temperature rise for each pound of water). This formula is altered when necessary
additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F)
- 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point
to-22°C (-8°F).
- 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of
-37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat,
temperature gauge, sending unit and heater are all designed for 50/50 glycol.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of
-59°C (-50°F)
CAUTION: Richer mixtures cannot be measured with field equipment. This can lead
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Coolant > Component Information > Description and Operation > Page
1430
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF + 4 Fluid Usage
Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage
NUMBER: 21-014-07
GROUP: Transmission
DATE: October 16, 2007
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14,
2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN
WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS.
SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602)
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1989 - 2003 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Truck
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue
1989 - 2004 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1990 - 1991 (AQ) Maserati
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2003 (BR/BE) Ram Truck
2004 - **2008** (CS) Pacifica
1998-2003 (DN) Durango
2002 - **2008** (DR/DH/D1) Ram Truck
2007 - **2008** (DC) Ram 3500 Cab Chassis
1995 - 2000 (FJ) Sebring/Avenger/Talon
1996 - 2000 (GS) Chrysler Voyager (International Market)
2004 - **2008** (HB) Durango
**2008 (HG) Aspen**
1995 - 2000 (JA) Cirrus/Stratus/Breeze
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF + 4 Fluid Usage > Page 1435
2007 - **2008** (JK) Wrangler
2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan
2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
**2007 - 2008 (KA) Nitro**
2002 - 2007 (KJ) Liberty
**2008 (KK) Liberty**
**2008 (L2) 300C (China)**
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - **2008** (LX/LE) 300/Magnum/Charger
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2005 (PL) Neon
2002 - 2003 (PG) PT Cruiser (International Markets)
2001 - **2008** (PT) PT Cruiser
1997 - 2002 (PR) Prowler
2001 - 2007 (RG) Chrysler Voyager (International Markets)
2001 - 2007 (RS) Town & Country/Caravan/Voyager
**2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)**
1997-2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines
1999 - 2004 (WJ) Grand Cherokee
2005 - **2008** (WK/WH) Grand Cherokee
2006 - **2008** (XK/XH) Commander
1989 - 1995 (YJ) Wrangler
**1989 - 2001 (XJ) Cherokee**
**1989 - 1993 (MJ) Comanche**
1996 - 1998 (ZG) Grand Cherokee (International Markets)
1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
**AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is
recommended for AW-4 (Asian Warner) transmissions**
NOTE:
This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM
vehicles equipped with Continuously Variable
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Technical Service Bulletins >
A/T - ATF + 4 Fluid Usage > Page 1436
Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a
W5J400 or NAG1 transmission (sales code DGJ).
DISCUSSION:
ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions.
ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions
EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE.
NOTE:
ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE
ANY OTHER FLUID.
NOTE:
ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be
used to top off vehicles that used ATF+3, ATF+2, or ATF+.
NOTE:
If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid
maintenance schedules listed for that model does not change. The service interval currently in
effect for a given model should continue to be followed. Refer to the Service or Owners manual for
maintenance schedule directions.
In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to
use ATF+4®
BENEFITS
^ Better anti-wear properties
^ Improved rust/corrosion prevention
^ Controls oxidation
^ Eliminates deposits
^ Controls friction
^ Retains anti-foaming properties
^ Superior properties for low temperature operation
FLUID COLOR
Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not
permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a
unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer
indicators of fluid condition and do not necessarily support a fluid change.
PARTS REQUIRED:
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid
31TH ....................................................................................................................................................
............................................................. 8.0L (8.5 Qt) 41TE .................................................................
................................................................................................................................................ 8.6L
(9.1 Qt)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Specifications > Capacity
Specifications > Page 1439
Fluid - A/T: Fluid Type Specifications
See TSB 21-010-06 4/14/2006
Transmission Fluid Type
Type
.........................................................................................................................................................
Mopar (R) ATF Plus 4 Type 9602, Or Equivalent
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check
Fluid - A/T: Service and Repair Fluid Level & Condition Check
Fluid Level
The transmission and differential sump have a common oil sump with a opening between the two.
The torque converter fills in both the "P" Park and "N" Neutral positions.
Place the selector lever in "P" Park to check fluid level.
The engine should be running at idle speed for at least one minute, with the vehicle on level
ground. This will assure complete oil level stabilization between differential and transmission.
The fluid should be at normal operating temperature (approximately 82 C. or 180 F).
The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator.
Fluid Condition
Along with fluid level, it is important to check the condition of the fluid.
- When the fluid smells burned, and is contaminated with metal or friction material particles, a
complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
- If there is any doubt about its condition, drain out a sample for a double check.
Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt.
Low Fluid Level Symptoms
Low fluid level can cause a variety of conditions because it allows the pump to take in air along with
the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be
low and build up slowly.
Improper Filling Level Symptoms
Improper filling can also raise the fluid level too high.
- When the transaxle has too much fluid, the gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can
interfere with normal valve, clutch and accumulator operation.
Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a
leak.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check > Page 1442
Fluid - A/T: Service and Repair Fluid and Filter Change
Fluid and Filter Change
When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission
Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also
the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is
disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - A/T > Component Information > Service and Repair > Fluid
Level & Condition Check > Page 1443
Fluid - A/T: Service and Repair Fluid Drain and Refill
Procedure
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan.
2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan.
3. Install a new filter and O-ring on bottom of the valve body.
4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to
19 Nm (165 in-lbs).
5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill
tube.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick.
CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil
(100F). Upper holes for hot oil (180F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region.
9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill
tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Capacity ...............................................................................................................................................
......................................................... 1.9L (4.0 Pints)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications >
Capacity Specifications > Page 1448
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Grade ...................................................................................................................................................
................................................................... API GL-5
Viscosity ..............................................................................................................................................
..................................................................... 85W-90
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Differential > Component Information > Specifications > Page
1449
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Power Transfer Unit .............................................................................................................................
........................................................ 1.2L (2.4 Pints)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Capacity Specifications > Page 1454
Fluid - Transfer Case: Fluid Type Specifications
Power Transfer Unit
Viscosity ..............................................................................................................................................
.............................................................. SAE 85W-90
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Fluid - Transfer Case > Component Information > Specifications >
Page 1455
Fluid - Transfer Case: Service Precautions
DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter Change ...............................................................................................................................
............................................................. 4.3L (4.5 Qt)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Capacity
Specifications > Page 1460
Engine Oil: Fluid Type Specifications
The content of this article reflects changes called for in TSB 26-11-97.
Engine Oil
API Classification .................................................................................................................................
........................................... SH or SH/CD or Above Above 0°F (-18°C) .............................................
.......................................................................................................................................................
10W-30 Below 32°F (0°C) ...................................................................................................................
.................................................................................... 5W-30
If vehicle operates on E-85 fuel either full or part-time, use only Mopar Flexible Fuel 5w-30 engine
oil or an equivalent that meets Chrysler standard MS-9214. SAE 5w-30 engine oil is preferred for
use in Flexible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage
may result.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1461
Engine Oil: Description and Operation
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED
ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR
HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN
RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR
DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conforms
to this service grade.
SAE VISCOSITY
Temperature/Engine Oil Viscosity
An SAE viscosity grade is used to specify the viscosity of engine oil. Use only, engine oils with
multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade
which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited
to your particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. They are designated as
either ENERGY CONSERVING or ENERGY CONSERVING II.
CONTAINER IDENTIFICATION
Engine Oil Container Standard Notations
Standard engine oil identification notations have been adopted to aid in the proper selection of
engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top
of engine oil cans.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1462
Engine Oil: Testing and Inspection
To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check
the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is
about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has
sat overnight.
3.0L Engine Dipstick
Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level
readings. Maintain the oil level between the MIN and MAX markings on the dipstick. Adding one
quart of oil when the reading is at the MIN mark will result in a MAX reading on these engines.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Engine Oil > Component Information > Specifications > Page 1463
Engine Oil: Service and Repair
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface
and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a
suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to
drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug
and gasket if damaged.
6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and
amount of engine oil described in this section. 8. Install oil fill cap. 9. Start engine and inspect for
leaks.
10. Stop engine and inspect oil level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Voyager/Caravan
2002 (PG) Chrysler PT Cruiser (International Markets)
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler
2002 - 2004 (PT) Chrysler PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/Caravan/Voyager
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe
1997 - 2004 (TJ) Wrangler
2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage > Page 1468
1999-2004 (WJ) Grand Cherokee
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH
vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved
service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and
MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is
no longer an indication of fluid condition.
The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number
for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA.
MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On
some past models, MS9602 should be used as the replacement fluid. On these models, if a power
steering system is being serviced that results in a large fluid loss, such as a pump, hose or
gear/rack replacement, the complete system should be drained and filled with MS9602.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage > Page 1469
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Technical Service
Bulletins > Steering - Power Steering Fluid Usage > Page 1470
NOTE:
This bulletin supersedes owner's and service manuals for the vehicles listed above that may state
to use MS9933 in the power steering system, and that may state not to use automatic transmission
fluid in the power steering system.
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications
Power Steering Fluid: Capacity Specifications
Capacity ...............................................................................................................................................
....................................................... 0.81 L (1.7 pints)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Capacity Specifications > Page 1473
Power Steering Fluid: Fluid Type Specifications
The recommended lubricant is Mopar Power Steering Fluid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Power Steering Fluid > Component Information > Specifications >
Page 1474
Power Steering Fluid: Service and Repair
WARNING: Fluid level should be checked with engine off to prevent injury from moving parts.
CAUTION: Do not use automatic transmission fluid in the power steering system. Do not overfill the
power steering system.
Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD
when fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). In all
pumps add fluid as necessary, use only Mopar Power Steering Fluid, or equivalent. DO NOT USE
ANY TYPE OF AUTOMATIC TRANSMISSION FLUID.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications
Refrigerant: Capacity Specifications
R134a Single Capacity ........................................................................................................................
........................................ 0.96 kg (34 oz. or 2.13 lbs)
R134a Dual Capacity ...........................................................................................................................
....................................... 1.36 kg (48 oz. or 3.00 lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Capacity
Specifications > Page 1479
Refrigerant: Fluid Type Specifications
Hydrofluorocarbon (HFC), ...................................................................................................................
............................................... R-134a liquefied gas
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant > Component Information > Specifications > Page 1480
Refrigerant: Description and Operation
This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear
colorless liquefied gas.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge
and/or poor performance. Never add any other type of refrigerant to a system designed to use
R-134a refrigerant. System failure will occur.
The high pressure service port is located on the liquid line near the strut tower. The low pressure
service port is located on the suction line near the compressor manifold.
Refrigerant Recovery/Recycling Station (Typical)
When servicing a system, it is required that an air conditioning charging recovery/recycling
machine be used. Contact an automotive service equipment supplier for proper equipment. Refer
to the operating instructions provided with the equipment for proper operation.
Manifold Gauge Set - Typical
A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling
device. Only use gauges that have not been used for R-12. The service hoses on the gauge set
should have manual (turn wheel) or automatic back flow valves at the service port connector ends.
This will prevent refrigerant R-134a from being released into the atmosphere.
R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the
oil that is specified on the under hood label.
Due to the different characteristics of R-134a it requires all new service procedures.
The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and
low global warming impact.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications
Refrigerant Oil: Capacity Specifications
Front A/C Compressor .........................................................................................................................
............................................................ 150 ml 5.0 oz.
Dual A/C Compressor ..........................................................................................................................
............................................................ 220 ml 7.4 oz.
Dual A/C Evaporator ............................................................................................................................
.............................................................. 60 ml 2.0 oz.
Condenser ...........................................................................................................................................
................................................................ 30 ml 1.0 oz.
Evaporator ...........................................................................................................................................
............................................................... 60 ml 2.0 oz. Filter-Drier ......................................................
................................................................................................................................................... 30 ml
1.0 oz.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Capacity
Specifications > Page 1485
Refrigerant Oil: Fluid Type Specifications
Synthetic-based, Polyalkylene Glycol ..................................................................................................
.......................................................................... ND-8
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fluids > Refrigerant Oil > Component Information > Specifications > Page
1486
Refrigerant Oil: Service and Repair
Refrigerant Oil Capacities
Refrigerant Oil Level Check When all air conditioning system is first assembled, all components
(except the compressor) are refrigerant oil free. After the system has been charged with R134a
refrigerant and operated, the oil in the compressor is dispersed through the lines and components.
The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the
Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of
refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained
in the rest of the system must be drained from the replacement compressor. When a line or
component has ruptured and oil has escaped, the compressor should be removed and drained.
The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus
the amount of oil still in the remaining components, can be measured and poured into the suction
port of the compressor.
Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz)
of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from
the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from
vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add
system capacity minus the capacity of components that have not been replaced through suction
port on compressor. Refer to the
Refrigerant Oil Capacity Chart.
6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake
System Bleeding Procedures
Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures
Bleeding Base Brake Hydraulic System
NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For
bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake
System bleeding procedure in antilock brakes.
Pressure Bleeding Procedure
CAUTION:
- Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid
reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid
reservoir.
- Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
- When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be
removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid
reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system
is pressurized.
Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment.
Air Trapped In Brake System
When bleeding the brake system, some air may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow
of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.
1. Remove the filler neck from the master cylinder fluid reservoir.
Pressure Bleeding Cap Installed On Master Cylinder
2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the
fluid reservoir of the master cylinder. Attach the
fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent.
3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar
containing fresh brake fluid.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake
System Bleeding Procedures > Page 1491
adequate removal of all trapped air from the brake hydraulic system.
(1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel
Rear Wheel Cylinder Bleeder Screw
4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow
of brake fluid.
CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid
discharge will NOT get all the air out.
5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free
flow is maintained in the hose and jar, this will
indicate a good bleed of the hydraulic system has been obtained.
6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been
improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to
monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the
brake system through the master cylinder.
7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Bleeding Without A Pressure Bleeder
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must
be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are
correctly adjusted.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure adequate removal of all trapped air from the brake
hydraulic system.
- Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed.
4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence.
This should pass a sufficient amount of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Brake Bleeding > System Information > Service and Repair > Base Brake
System Bleeding Procedures > Page 1492
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
Bleeding Teves Mark 20 Hydraulic System
The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to
disconnection of brake lines, hoses or components. The ABS system, particularly the HCU, should
only be bled when the HCU is replaced or it is removed from the vehicle, or if there is reason to
believe the HCU has ingested air. Under most circumstances that would require brake bleeding,
only the base brake hydraulic system needs to be bled.
It is important to note that excessive air in the brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level
in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding
procedure and add DOT 3 brake fluid as required.
The ITT Teves Mark 20 ABS must be bled as two independent braking systems. The non ABS
portion of the brake system is to be bled the same as any non ABS system. This brake system can
be either pressure bled or manually bled.
The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires
the use of the DRB Diagnostic Tester and the bleeding sequence procedure outlined below.
ABS BLEEDING PROCEDURE
When bleeding the ABS system, the following bleeding sequence MUST be followed to insure
complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure
or standard pressure bleeding equipment.
If the brake system is to be bled using pressurized bleeding equipment, refer to Bleeding Base
Brakes. 1. Assemble and install all brake system components on the vehicle making sure all
hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to
the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the
instrument panel to the left of the steering column cover.
3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault
codes stored. If it does, remove them using
the DRB.
WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube must be
attached to the bleeder screws and submerged in a clear container filled part way with clean brake
fluid. Direct the flow of brake fluid away from the painted surfaces of the vehicle. Brake fluid at high
pressure may come out of the bleeder screws when opened.
4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5.
Using the DRB, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed
ABS" cycle one time. Release the brake
pedal.
6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6
above until brake fluid flows clear and is free of any air bubbles. Check brake fluid level in reservoir
periodically to prevent reservoir from running low on brake fluid.
8. Test drive the vehicle to be sure brakes are operating correctly and that the brake pedal does
not feel spongy.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Air Bag(s) Arming and Disarming > System Information > Service and Repair >
Air Bag Disarming > Page 1498
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center
Fuse: Locations Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1504
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1505
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1506
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1507
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1508
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1509
Fuse: Locations Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1510
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1511
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1512
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse > Component Information > Locations >
Power Distribution Center > Page 1513
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block
Fuse Block: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1518
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1519
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1520
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1521
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1522
Fuse Block: Diagrams Power Distribution Block
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1523
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1524
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1525
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1526
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Fuse Block > Component Information >
Diagrams > Junction Block > Page 1527
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Locations
Relay Box: Locations
ABS Fuses
ABS Fuses
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block
Relay Box: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1533
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1534
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1535
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1536
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1537
Relay Box: Diagrams Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1538
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1539
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1540
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1541
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Fuses and Circuit Breakers > Relay Box > Component Information > Diagrams
> Junction Block > Page 1542
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Service Reminder Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
This vehicle does not have a Maintenance Reminder Light option.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Tires > Spare Tire > Component Information > Description
and Operation
Spare Tire: Description and Operation
The temporary spare tire is designed for emergency use only. The original tire should be repaired
and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH
when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete
details.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1560
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1561
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1562
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1563
WHEEL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1564
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1565
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1566
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road Vibration/Shake/Wobble. >
Page 1567
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1573
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1574
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1575
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1576
WHEEL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1577
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1578
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1579
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 1580
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Technical Service
Bulletins > Page 1581
Wheels: Description and Operation
Original equipment wheels are designed for proper operation at all loads up to the specified
maximum vehicle capacity.
All models use steel or aluminum drop center wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety humps.
Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised
sections hold the tire in position on the wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and
special wheel clamps for the alignment equipment.
Do not use replacement parts of lesser quality or of a substitute design from the original equipment
part.
All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary
to ensure proper retention of the wheels.
Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface.
CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel
lug nuts. This could adversely affect the safety and handling of your vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection
> General Information
Wheels: Testing and Inspection General Information
Wheels must be replaced if they:
- Have excessive run out
- Are bent or dented
- Leak air
- Have damaged wheel lug holes
Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed.
Original equipment replacement wheels are available through the dealer. When obtaining
replacement wheels from any other source, they must be equivalent in load carrying capacity. The
wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match
the original equipment wheels.
CAUTION: Failure to use original equipment replacement wheels may adversely affect the safety
and handling of your vehicle.
CAUTION: Replacement with used wheels is not recommended. The service history of the rim may
have included severe treatment or very high mileage. The rim could fail without warning.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection
> General Information > Page 1584
Wheels: Testing and Inspection Tire and Wheel Runout
NOTE: Runout should always be measured off the vehicle and on a suitable balance machine.
GENERAL INFORMATION
Radial run out is the difference between the high and low points on the outer edge of the tire or
wheel. Lateral run out is the total side-to-side wobble of the tire or wheel. Radial run out of more
than 0.762 mm (0.030 inch) measured at the center line of the tread may cause the vehicle to
shake. Lateral run out of more than 0.762 mm (0.030 inch) measured at the side of the tire as close
to the tread as possible may cause the vehicle to shake. Sometimes radial run out can be reduced
by relocating the wheel and tire on the wheel studs (See Method 1). If this does not reduce run out
to an acceptable level, the tire can be rotated on the wheel. (See Method 2).
Method 1 (Relocate Wheel On Hub) Check accuracy of the wheel mounting surface; adjust wheel
bearings. Drive vehicle a short distance to eliminate tire flat spotting from a parked position.
Fig. 2
Verify all wheel nuts are properly torqued.
Fig. 3
Use run out gauge D-128-TR, or equivalent to determine run out. Relocate the wheel on the
mounting studs, two studs over from the original position. Retighten wheel nuts until all are properly
torqued. This will prevent brake distortion.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection
> General Information > Page 1585
Check radial run out. If still excessive, mark tire sidewall, wheel, and stud at point of maximum run
out and proceed to Method 2.
Method 2 (Relocate Tire On Wheel) Rotating tire on wheel is particularly effective when there is run
out in both tire and wheel. Remove tire from wheel and remount wheel on hub in former position.
Fig. 5
Check wheel radial run out. It should be no more than 0.5 mm (0.020 inch) for steel wheels and
0.38 mm (0.015 inch) for cast aluminum wheels.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Testing and Inspection
> General Information > Page 1586
Fig. 6
Check wheel lateral run out. It should be no more than 0.8 mm (0.032 inch). If the point of greatest
wheel radial run out is near the original chalk mark, remount the tire on the rim 180 degrees from
its original position. Recheck the run out. If this does not reduce the run out to an acceptable level,
replace the wheel and/or the tire.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Balance
Wheels: Service and Repair Balance
Balancing need is indicated by vibration of seats, floor pan, or steering wheel. The vibration will be
noticed mostly when driving over 90 km/h (55 mph) on a smooth road.
It is recommended that a two plane dynamic balancer be used when a wheel and tire assembly
require balancing. Static balancing should be used only when a two plane balancer is not available.
Off-vehicle tire and wheel balancing is recommended to be used on this vehicle.
NOTE: If on vehicle equipment is being used to balance the tire/wheel assemblies, remove the
opposite tire/wheel from the vehicle.
Fig. 7
For static balancing, find the location of heavy spot on tire/wheel causing the imbalance. Counter
balance wheel directly opposite the heavy spot. Determine weight required to counterbalance the
area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer
rim flange.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Balance > Page 1589
Fig. 8
For dynamic balancing, the balancing equipment is designed to indicate the location and amount of
weight to be applied to both the inner and outer rim flanges.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheels > Component Information > Service and Repair >
Balance > Page 1590
Wheels: Service and Repair Installation
Fig. 2
To install the wheel, first position it properly on the mounting surface of the hub using the hub pilot
as a guide. All wheel nuts should be lightly tightened before progressively tightening them in the
proper sequence. Then fully tighten the wheel nuts in the proper sequence to a torque of 135 Nm
(100 ft. lbs.). Never use oil or grease on studs or nuts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
> Page 1594
Wheel Bearing: Description and Operation
The rear hub and bearing assembly used on this vehicle is serviceable only as a complete
assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort
to repair it.
The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are
removable from the back of the rear hub/bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
> Page 1595
Wheel Bearing: Testing and Inspection
The rear hub and bearing assembly is designed for the life of the vehicle and should require no
maintenance. The following procedure may be used for evaluation of bearing condition.
With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral
play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings
exhibit these conditions during inspection, the hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive grease loss may also require bearing
replacement. Moderate grease loss from bearing is considered normal and should not require
replacement of the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
> Page 1596
Wheel Bearing: Service and Repair
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and
tire. 3. Remove brake drum from hub/bearing.
4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed
sensor during removal and installation of the
hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless
the speed sensor is removed first.
CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on
the tone wheel will result in false ABS cycling and corrosion of the tone wheel.
5. Remove the 4 bolts attaching the hub/ bearing to the rear axle.
CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the
hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle
by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on
the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in
noise or failure of the bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Bearing > Component Information > Specifications
> Page 1597
6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or
equivalent and following procedure to press the
hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and
against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of
Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the
bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should
be against and supported by the axle plate when pressing the wheel bearing out of the axle. If
Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the
flashing from the hole until tool fits properly.
d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or
equivalent. Tighten bolt against Special Tool 8214-1
or equivalent.
e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special
Tool 8214-1 or equivalents.
Removing Rear Hub/Bearing From Axle
7. Remove the hub/bearing from the rear axle and brake support plate.
INSTALL
1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2.
Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3.
Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle.
4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the
proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence
Wheel Fastener: Specifications Wheel Tightening Sequence
Wheel Torque Sequence - Master
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence > Page 1606
Wheel Fastener: Specifications Lug Nut Torque
Lug Nut Torque ....................................................................................................................................
................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ...........................................................
...........................................................................................................................................................
19 mm
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Wheel Tightening Sequence > Page 1607
Wheel Fastener: Specifications Wheel Stud Size
Mounting Stud Size .............................................................................................................................
........................................................... M12 x 1.5 mm
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Specifications
> Page 1608
Wheel Fastener: Description and Operation
The wheel studs and nuts are designed for the specific wheel applications used on a vehicle and
must be replaced with equivalent parts.
If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT
be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange,
damage to the hub and bearing assembly will occur leading to premature bearing failure.
Use the procedure and special tools shown in the service procedures section for the wheel
mounting studs when replacing the wheel attaching studs.
The hub and bearing assembly does not require removal from the steering knuckle or the rear
knuckle to replace the wheel attaching studs in the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front
Wheel Fastener: Service and Repair Front
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing assembly will occur leading to premature
bearing failure.
REMOVE
The following procedure and special tools shown MUST BE used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the steering knuckle to
replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or
centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the
vehicle.
3. Remove the front caliper assembly from the front steering knuckle assembly. Refer to Brakes
and Traction Control for caliper removal
procedure.
4. Remove front rotor from hub, by pulling it straight off wheel mounting studs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1611
5. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly, so the
threads on the stud are even with end of lug nut.
Install Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and
wheel stud.
6. Tightening down on special tool will push wheel stud out of the hub and bearing assembly
flange. When shoulder of wheel stud is past flange
remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel
stud from flange.
INSTALL
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back
over braking disc and align with caliper mounting holes on steering knuckle. Refer to Brakes and
Traction Control
for caliper installation procedure. Install the caliper adapter to steering knuckle attaching bolts and
torque to 19 Nm (168 inch lbs.).
5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
6. Lower vehicle to the ground.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Maintenance > Wheels and Tires > Wheel Fastener > Component Information > Service and
Repair > Front > Page 1612
Wheel Fastener: Service and Repair Rear
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub
and bearing failure.
REMOVE
The following procedure and special tools shown MUST be used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the rear axle for replacement
of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type
hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum.
4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the
threads on stud are even with end of lug nut. Install
Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and wheel
stud.
5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly
flange. Remove lug nut from stud and remove wheel
stud from flange.
INSTALL
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly
on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to
half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
5. Lower vehicle to the ground.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications
Compression Check: Specifications
Compression Ratio ..............................................................................................................................
........................................................................... 8.9:1 Minimum Compression ...................................
........................................................................................................................................ 689.5 kPa
(100 psi) Maximum Variation Between Cylinders ................................................................................
......................................................................................... 25%
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Compression Check > System Information >
Specifications > Page 1618
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. Ensure the battery is completely charged and the engine starter motor is in good
operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis
purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System (DIS) disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to
specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and
secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and
different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and
Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt
drives. 18. Road test vehicle as a final test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service
Camshaft Bearing: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service
NUMBER: 09-007-02
GROUP: Engine
DATE: Oct. 21, 2002
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED
NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS.
SUBJECT: Camshaft/Bearing Service
MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager
(International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG)
Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES
CODES EGA, EGB, EGH, EGM, EGP).
DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings
must be inspected for wear and/or damage. If wear or damage is present the short block must be
replaced. Excessive camshaft bearing wear could result in damage to the new replacement
camshaft. Camshaft bearings are only serviced with a short engine assembly.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Technical Service Bulletins > Page 1624
Camshaft Bearing: Specifications
DIAMETER:
No. 1
..............................................................................................................................................................
50.825 - 50.800 mm (2.0009 - 1.9999 inch) No. 2
..............................................................................................................................................................
50.419 - 50.393 mm (1.9849 - 1.9839 inch) No. 3
..............................................................................................................................................................
50.038 - 50.013 mm (1.9699 - 1.9690 inch) No. 4
..............................................................................................................................................................
49.632 - 49.606 mm (1.9540 - 1.9529 inch)
Oil Clearance
.........................................................................................................................................................
0.0254 - 0.0762 mm (0.001 - 0.003 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Bearing > Component Information > Technical Service Bulletins > Page 1625
Camshaft Bearing: Service and Repair
REMOVAL
1. With engine removed from vehicle and completely disassembled, drive out rear cam bearing
core hole plug.
Removed Installation Of Camshaft Bearings With Tool C-3132-A-Typical
2. Install proper size adapters and horseshoe washers (part of Tool C-3132-A) at back of each
bearing shell to be removed and drive out bearing
shells.
INSTALLATION
1. Install new camshaft bearings with Tool C-3132-A by sliding the new camshaft bearing shell over
proper adapter. 2. Position rear bearing in the tool. Install horseshoe lock and by reversing removal
procedure, carefully drive bearing shell into place. 3. Install remaining bearings in the same
manner. Bearings must be carefully aligned to bring oil holes into full register with oil passages
from the
main bearing. Number two bearing must index with the oil passage to the left cylinder head and
Number three bearing must index with the oil passage to the right cylinder head. If the camshaft
bearing shell oil holes are not in exact alignment, remove End reinstall them correctly. Install a new
core hole plug at the rear of camshaft. Be sure this plug does not leak.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft
Gear/Sprocket > Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
.................................................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft Thrust
Plate > Component Information > Specifications
Camshaft Thrust Plate: Specifications
Thrust Plate Bolt ..................................................................................................................................
............................................... 12 Nm (105 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Technical Service Bulletins > Engine - Camshaft/Bearing Inspection/Service
Camshaft: Technical Service Bulletins Engine - Camshaft/Bearing Inspection/Service
NUMBER: 09-007-02
GROUP: Engine
DATE: Oct. 21, 2002
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 09-008-01 DATED
NOVEMBER 2, 2001, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS.
SUBJECT: Camshaft/Bearing Service
MODELS: 1993 - **1997** (LH) Intrepid/Concorde/Vision 1996 - 2000 (GS) Chrysler Voyager
(International Markets) 1996 - 2000 (NS) Town & Country/Caravan/Voyager 2001 - **2003** (RG)
Chrysler Voyager (International Markets) 2001 - **2003** (RS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE (SALES
CODES EGA, EGB, EGH, EGM, EGP).
DISCUSSION: When it is necessary to replace a camshaft for any reason, the camshaft bearings
must be inspected for wear and/or damage. If wear or damage is present the short block must be
replaced. Excessive camshaft bearing wear could result in damage to the new replacement
camshaft. Camshaft bearings are only serviced with a short engine assembly.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Technical Service Bulletins > Page 1636
Camshaft: Specifications
Camshaft
Drive ....................................................................................................................................................
..................................................................... Chain Bearings ..............................................................
.............................................................................................................................. Steel Backed
Babbitt Number ....................................................................................................................................
........................................................................................ 4 Diametrical Clearance
...............................................................................................................................................
0.025-0.101 mm (0.001-0.004 inch)
Max Allowable .....................................................................................................................................
................................... 0.127 mm (0.005 inch)
Thrust Taken By ..................................................................................................................................
........................................................... Thrust Plate End Play ..............................................................
...................................................................................................... 0.127-0.304 mm (0.005-0.012
inch)
Max. Allowable ....................................................................................................................................
................................... 0.304 mm (0.012 inch)
Camshaft Journals
Bearing Journal Diameter No. 1
............................................................................................................................ 50.724-50.775 mm
(1.997-1.999 inch) Bearing Journal Diameter No. 2
........................................................................................................................ 50.317-50.368 mm
(1.9809-1.9829 inch) Bearing Journal Diameter No. 3
........................................................................................................................ 49.936-49.987 mm
(1.9659-1.9679 inch) Bearing Journal Diameter No. 4
........................................................................................................................ 49.530-49.581 mm
(1.9499-1.9520 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Camshaft,
Engine > Component Information > Technical Service Bulletins > Page 1637
Camshaft: Service and Repair
REMOVAL-ENGINE REMOVED FROM VEHICLE
Remove intake manifold, cylinder head covers, cylinder heads, timing chain case cover and timing
chain. 1. Remove rocker arm and shaft assemblies. 2. Remove push rods and tappets; identify so
each part will be replaced in its original location.
Camshaft Thrust Plate
3. Remove camshaft thrust plate 4. Install a long bolt into front of camshaft to facilitate removal of
the camshaft; remove camshaft, being careful not to damage cam bearings with the
cam lobes.
INSTALLATION
1. Lubricate camshaft lobes and camshaft bearing journals and insert the camshaft to within 2
inches of its final position in cylinder block. 2. Install camshaft thrust plate with two screws as
shown in image. Tighten to 12 Nm (105 inch lbs.) torque. 3. Rotate crankshaft so the timing arrow
is at the 12 o'clock position. 4. Place timing chain around camshaft sprocket and place the timing
mark to the 6 o'clock position. 5. Align the dark colored links with the dot on the camshaft sprocket,
place timing chain around crankshaft sprocket with the dark colored link lined
up with the dot on the sprocket and install camshaft sprocket into position.
Alignment Of Timing Marks
6. Using straight edge to check alignment of timing marks. 7. Install the camshaft bolt. Tighten bolt
to 54 Nm (40 ft. lbs.). 8. Rotate crankshaft 2 revolutions. Timing marks should line up. If timing
marks do not line up, remove cam sprocket and realign. 9. Measure camshaft end play. End Play
should measure 0.0127 to 0.304 mm (0.005 to 0.012 inches.) 0.310 mm (0.012 inch Max.). If not
within
limits install a new thrust plate.
10. Each tappet reused must be installed in the same position from which it was removed. When
camshaft is replaced, all of the tappets must be
replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Specifications
Lifter / Lash Adjuster: Specifications
GENERAL SPECIFICATIONS
Type .....................................................................................................................................................
.................................................... Roller Hydraulic Body Diameter
......................................................................................................................................................
22.95-22.96 mm (0.9035-0.9040 inch) Clearance in Block
....................................................................................................................................................
0.02-0.06 mm (0.0007-0.0024 inch) Service Tappets Available
................................................................................ STD., 0.025 mm (0.001), 0.20 mm (0.008 inch),
0.762 mm (0.030 inch)
TORQUE SPECIFICATIONS
Tappet Retainer Yoke Bolt
..............................................................................................................................................................
12 Nm (105 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Testing and Inspection > Diagnosis and Testing
Lifter / Lash Adjuster: Testing and Inspection Diagnosis and Testing
Roller Tappets Aligning Yoke And Retainer
HYDRAULIC TAPPETS
The valve train includes roller tappet assemblies, aligning yokes and yoke retainer. Roller tappet
alignment is maintained by machined flats on tappet body being fitted in pairs into six aligning
yokes. The yokes are secured by an alignment yoke retainer.
Preliminary Step To Checking The Hydraulic Tappets
Before disassembling any part of the engine to correct tappet noise, read the oil pressure at the
gauge. Install a reliable gauge at pressure sending unit if vehicle has no oil pressure gauge and
check the oil level in the oil pan. The pressure should be between 30 and 80 psi (206.8 to 551.6
kPa) at 2000 rpm. The oil level in the pan should never be above the MAX mark on dipstick, or
below the MIN mark. Either of these two conditions could be responsible for noisy tappets. Oil
Level Check: stop engine after reaching normal operating temperature. Allow 5 minutes to stabilize
oil level, check dipstick.
Oil Level Too High
If oil level is above the MAX mark on dip stick, it is possible for the connecting rods to dip into the
oil while engine is running and create foam. Foam in oil pan would be fed to the hydraulic tappets
by the oil pump causing them to become soft and allow valves to seat noisily.
Oil Level Too Low
Low oil level may allow pump to take in air which when fed to the tappets, causes them to become
soft and allows valves to seat noisily. Any leaks on intake side of pump through which air can be
drawn will create the same tappet action. Check the lubrication system from the intake strainer to
the pump cover, including the relief valve retainer cap. When tappet noise is due to aeration, it may
be intermittent or constant, and usually more than one tappet will be noisy. When oil level and
leaks have been corrected, engine should be operated at fast idle to allow all of the air inside of the
tappets to be bled out.
Valve Train Noise Diagnosis
To determine source of valve train noise, operate engine at idle with cylinder head covers removed
and listen for source of the noise.
NOTE: Worn valve guides or cocked springs are sometimes mistaken for noisy tappets. If such is
the case, noise may be dampened by applying side thrust on the valve spring. If noise is not
appreciably reduced, it can be assumed the noise is in the tappet. Inspect the rocker arm push rod
sockets and push rod ends for wear.
Valve tappet noise ranges from light noise to a heavy click. A light noise is usually caused by
excessive leak-down around the unit plunger which will necessitate replacing the tappet, or by the
plunger partially sticking in the tappet body cylinder. A heavy click is caused either by a tappet
check valve not seating, or by foreign particles becoming wedged between the plunger and the
tappet body causing the plunger to stick in the down position. This heavy click will be accompanied
by excessive clearance between the valve stem and rocker arm as valve closes. In either case,
tappet assembly should be removed for inspection and cleaning.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Testing and Inspection > Diagnosis and Testing > Page 1643
Lifter / Lash Adjuster: Testing and Inspection Lash Adjuster Diagnosis
A tappet-like noise may be produced from several items. Check the following items. 1. Engine oil
level too high or too low. This may cause aerated oil to enter the adjusters and cause them to be
spongy. 2. Insufficient running time after rebuilding cylinder head. Low speed running up to 1 hour
may be required. 3. During this time, turn engine off and let set for a few minutes before restarting.
Repeat this several times after engine has reached normal operating
temperature.
4. Low oil pressure. 5. The oil restrictor pressed into the vertical oil passage to the cylinder head is
plugged with debris. 6. Air ingested into oil due to broken or cracked oil pump pick up. 7. Worn
valve guides. 8. Rocker arm ears contacting valve spring retainer. 9. Rocker arm loose, adjuster
stuck or at maximum extension and still leaves lash in the system.
10. Faulty lash adjuster.
a. Check lash adjusters for sponginess while installed in cylinder head. Depress part of rocker arm
over adjuster. Normal adjusters should feel
very firm. Spongy adjusters can be bottomed out easily.
b. Remove suspected lash adjusters, and disassemble Do not reuse retainer caps. Do not
interchange parts and make sure that care and cleanliness
is exercised in the handling of parts.
c. Clean out dirt and varnish with solvent. d. Reassemble with engine oil. e. Check for sponginess.
f.
If still spongy, replace with new adjuster.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Removal and Installation
Lifter / Lash Adjuster: Service and Repair Removal and Installation
1. Refer to Cylinder Head Removal. Cylinder Head must be removed to gain access to tappets for
service. 2. Remove yoke retainer and aligning yokes. 3. Use Tool C-4129 to remove tappets from
their bores. If all tappets are to be removed, identify tappets to insure installation in original
location.
NOTE: If the tappet or bore in cylinder block is scored, scuffed, or shows signs of sticking, ream the
bore to next oversize and replace with oversize tappet.
CAUTION: The plunger and tappet bodies are not interchangeable. The plunger and valve must
always be fitted to the original body. It is advisable to work on one tappet at a time to avoid mixing
of parts. Mixed parts are not compatible. Do not disassemble a tappet on a dirty work bench.
INSTALLATION
1. Lubricate tappets. 2. Install tappets in their original positions.
Roller Tappets Aligning Yoke And Retainer
3. With roller tappets, install aligning yokes. 4. Install yoke retainer and torque screws to 12 Nm
(105 inch lbs.). 5. Install cylinder heads. Refer to cylinder head installation. 6. Start and operate
engine. Warm up to normal operating temperature.
CAUTION: To prevent damage to valve mechanism, engine must not be run above fast idle until all
hydraulic tappets have filled with oil and have become quiet.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Lifter / Lash
Adjuster, Valve > Component Information > Service and Repair > Removal and Installation > Page 1646
Lifter / Lash Adjuster: Service and Repair Disassembly and Assembly
Hydraulic Roller Tappet Assembly
1. Pry out plunger retainer spring clip. 2. Clean varnish deposits from inside of tappet body above
plunger cap. 3. Invert tappet body and remove plunger cap, plunger, flat or ball check valve, check
valve spring, check valve retainer and plunger spring. Check
valve could be flat or ball.
ASSEMBLY
1. Clean all tappet parts in a solvent that will remove all varnish and carbon. 2. Replace tappets
that are unfit for further service with new assemblies. 3. If plunger shows signs of scoring or wear,
valve is pitted, or valve seat on end of plunger indicates any condition that would prevent valve
from
seating, install a new tappet assembly.
4. Assemble tappets.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Shaft Bracket Bolts ..................................................................................................................
............................................... 28 Nm (250 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Camshaft, Lifters and Push Rods > Rocker Arm
Assembly > Component Information > Specifications > Page 1650
Rocker Arm Assembly: Service and Repair
REMOVAL
1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling on the boot
straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head
cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and
shaft assembly.
Rocker Arm Location Left Bank
7. If rocker arm assemblies are disassembled for cleaning or replacement. Assemble rocker arms
in their original position. Refer to image for rocker
arm for positioning on the shaft.
INSTALLATION
1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions,
tighten to 28 Nm (250 inch lbs.).
CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts.
Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine
operation.
2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if
necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover
fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install spark
plug wires. 6. Install upper intake manifold assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Specifications
Connecting Rod Bearing: Specifications
Bearing Clearance
........................................................................................................................................... 0.019 0.065 mm (0.00075 - 0.0026 inch)
Wear Limit ...........................................................................................................................................
............................................ 0.76 mm (0.003 inch)
Side Clearance
.......................................................................................................................................................
0.127 - 0.381 mm (0.005 - 0.015 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings
Connecting Rod Bearing: Service and Repair Fitting Connecting Rod Bearings
Fit all rods on one bank until complete. The bearing caps are not interchangeable and should be
marked at removal to insure correct assembly. The bearing shells must be installed with the tangs
inserted into the machined grooves in the rods and caps. Install cap with the tangs on the same
side as the rod. Limits of taper or out-of-round on any crankshaft journals should be held to 0.025
mm (0.001 inch). Bearings are available in 0.025 mm (0.001 inch) and 0.250 mm (0.010 inch)
undersize. Install the bearings in pairs. Do not use a new bearing half with an old bearing half. Do
not file the rods or bearing caps.
Piston Ring Specification Chart
1. Follow procedure specified in the Standard Service Procedure Section for Measuring Main
Bearing Clearance and Connecting Rod Bearing
Clearance.
Measure Crankshaft Journal O.D.
NOTE: The rod bearing bolts should be examined before reuse. If the threads are necked down the
bolts should be replaced. Necking can be checked by holding a scale or straight edge against the
threads. If all the threads do not contact the scale the bolt should be replaced.
2. Before installing the nuts the threads should be oiled with engine oil. 3. Install nuts finger tight on
each bolt then alternately torque each nut to assemble the cap properly. 4. Tighten the nuts to 54
Nm + 1/4 turn (40 ft. lbs. + 1/4 turn).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1657
Checking Connecting Rod Side Clearance
Check For Streched (Necked) Bolts
CONNECTING ROD SPECIFICATION CHART
5. Using a feeler gauge, check connecting rod side clearance. Refer to Connecting Rod
Specification Chart.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1658
Connecting Rod Bearing: Service and Repair Main Bearing and Connecting Rod Bearing
Clearances
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use of Plastigage:
NOTE: The total clearance of the main bearings can only be determined by removing the weight of
the crankshaft. This can be accomplished by either of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance
between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum
of 0.254 mm (0.010 inch) shim (e. g. cardboard, match-book cover, etc.) between the bearing shell
and the bearing cap on the adjacent bearings and tightening bolts to 14-20 Nm (10-15 ft. lbs.). The
number of main bearing will vary from engine to engine.
ENGINE WITH 5 MAIN BEARINGS
- When checking #1 main bearing shim #2 main bearing.
- When checking #2 main bearing shim #1 & 3 main bearing.
- When checking #3 main bearing shim #2 & 4 main bearing.
- When checking #4 main bearing shim #3 & 5 main bearing.
- When checking #5 main bearing shim #4 main bearing.
ENGINE WITH 4 MAIN BEARING
- When checking #1 main bearing shim #2 main bearing.
- When checking #2 main bearing shim #1 & #3 main bearing.
- When checking #3 main bearing shim #2 & #4 main bearing.
- When checking #4 main bearing shim #3 main bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEMBLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the
bearing being checked.
PLASTIGAGE PROCEDURE
1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
Plastigage Placed In Lower Shell
2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately
6.35 mm (1/4 inch) off center and away from the
oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale
provided on the package. Locate the band closest
to the same width. This band shows the amount of clearance in thousandths of a millimeter.
Differences in readings between the ends indicate the amount of taper present. Record all readings
taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a
metric scale.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent.
The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft
until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface
to be checked. Plastigage is soluble in oil.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod Bearing
> Component Information > Service and Repair > Fitting Connecting Rod Bearings > Page 1659
3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap
approximately 6.35 mm (1/4 inch) off center and away
from the oil hole. In addition, suspect areas can be checked by placing Plastigage in the suspect
area.
4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do
not rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inaccurate results.
Clearance Measurement
5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Locate the band closest to the
same width. This band indicates the amount of oil clearance. Differences in readings between the
ends indicate the amount of taper present. Record all readings taken. Plastigage generally is
accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing
clearance exceeds 0.076 mm (0.003 inch) replace bearing.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts
Connecting Rod: Specifications Connecting Rod Cap Bolts/Nuts
TORQUE SPECIFICATIONS
Rod Nut ...............................................................................................................................................
........................... 54 Nm (40 ft. lbs.) plus 1/4 turn
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Connecting Rod Cap Bolts/Nuts > Page 1664
Connecting Rod: Specifications Connecting Rod Specifications
Connecting Rod
Bearing Type .......................................................................................................................................
..................................... Aluminum Lead (Bimetal) Bearing Clearance
...............................................................................................................................................
0.019-0.065 mm (0.00075-0.0026 inch) Max. Allowable .....................................................................
........................................................................................................ 0.076 mm (0.003 inch) Side
Clearance
...........................................................................................................................................................
0.127-0.381 mm (0.005-0.015 inch)
Connecting Rod Journals
Diameter
............................................................................................................................................................
58.005-57.979 mm (2.2837-2.2827 inch) Out-of-Round (Max.) ..........................................................
........................................................................................................... 0.025 mm (0.001 inch) Taper
(Max.) ..................................................................................................................................................
................................ 0.025 mm (0.001 inch)
TORQUE SPECIFICATIONS
Rod Nut ...............................................................................................................................................
............................ 54 Nm (40 ft. lbs.) plus 1/4 turn
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Page 1665
Connecting Rod: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove cylinder heads and oil pan. 3. Remove top
ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be
sure to keep tops of pistons
covered during this operation. Pistons and connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so
that each connecting rod is centered in cylinder bore.
Identify Connecting Rod To Cylinder
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if
necessary.
Connecting Rod Protectors
5. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push
each piston and rod assembly out of cylinder
bore.
NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.
INSTALLING PISTON AND CONNECTING ROD ASSEMBLY
Piston Ring End Gap Position
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Connecting Rod, Engine
> Component Information > Specifications > Page 1666
1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
with oil ring rail gap.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the
rail gaps located as shown in image. 3. Lubricate the piston and rings with clean engine oil.
Position a ring compressor over the piston and rings, and tighten the compressor. Be sure
position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts.
Piston-Installation
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod
over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide
connecting rod into position on connecting rod journal.
Piston I.D. Notches
7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps.
Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lbs.) Plus 1/4 turn. 9.
Repeat procedure for each piston and rod installation.
10. Install cylinder heads and oil pan. 11. Fill engine crankcase with proper oil to correct level. 12.
Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Specifications
Crankshaft Main Bearing: Specifications
Crankshaft Cast Nodular Iron
Thrust Location No. 2 Bearing
Connecting Rod Journal Diameter 2.124 - 2.125 in
Main Bearing Diametrical Clearance No.1-4 0.0043 - 0.0023 in
Max. Allowable 0.004 in
End Play 0.0036 - 0.0095 in
Max. Allowable 0.015 in
Main Bearing Journals Diameter 2.5202 - 2.5195 in
Out-of-Round 0.001 in
Taper (Max.) 0.001 in
Connecting Rod Journals Diameter 2.2837 - 2.2827 in
Out-of-Round 0.001 in
Taper (Max.) 0.001 in
Main Bearing Cap Bolts 30 ft.lb
plus 1/4 turn
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Inspection
Crankshaft Main Bearing: Service and Repair Inspection
PLASTIGAGE METHOD
Engine crankshaft bearing clearances can be determined by use of Plastigage or equivalent. The
following is the recommended procedure for the use of Plastigage:
NOTE: The total clearance of the main bearings can only be determined by removing the weight of
the crankshaft. This can be accomplished by either of two methods:
PREFERRED METHOD
Shimming the bearings adjacent to the bearing to be checked in order to remove the clearance
between upper bearing shell and the crankshaft. This can be accomplished by placing a minimum
of 0.254 mm (0.010 inch) shim (e. g. cardboard, match-book cover, etc.) between the bearing shell
and the bearing cap on the adjacent bearings and tightening bolts to 14-20 Nm (10-15 ft. lbs.). The
number of main bearing will vary from engine to engine.
ENGINE WITH 5 MAIN BEARINGS
- When checking #1 main bearing shim #2 main bearing.
- When checking #2 main bearing shim #1 & 3 main bearing.
- When checking #3 main bearing shim #2 & 4 main bearing.
- When checking #4 main bearing shim #3 & 5 main bearing.
- When checking #5 main bearing shim #4 main bearing.
ENGINE WITH 4 MAIN BEARING
- When checking #1 main bearing shim #2 main bearing.
- When checking #2 main bearing shim #1 & #3 main bearing.
- When checking #3 main bearing shim #2 & #4 main bearing.
- When checking #4 main bearing shim #3 main bearing.
NOTE: REMOVE ALL SHIMS BEFORE REASSEMBLING ENGINE
ALTERNATIVE METHOD
The weight of the crankshaft can be supported by a jack under the counterweight adjacent to the
bearing being checked.
PLASTIGAGE PROCEDURE
1. Remove oil film from surface to be checked. Plastigage is soluble in oil.
Plastigage Placed In Lower Shell
2. Place a piece of Plastigage across the entire width of the bearing shell in the cap approximately
6.35 mm (1/4 inch) off center and away from the
oil holes. (In addition, suspected areas can be checked by placing the Plastigage in the suspected
area). Torque the bearing cap bolts of the bearing being checked to the proper specifications.
3. Remove the bearing cap and compare the width of the flattened Plastigage with the metric scale
provided on the package. Locate the band closest
to the same width. This band shows the amount of clearance in thousandths of a millimeter.
Differences in readings between the ends indicate the amount of taper present. Record all readings
taken. Plastigage generally is accompanied by two scales. One scale is in inches, the other is a
metric scale.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
CONNECTING ROD BEARING CLEARANCE
Engine connecting rod bearing clearances can be determined by use of Plastigage or equivalent.
The following is the recommended procedure for the use of Plastigage: 1. Rotate the crankshaft
until the connecting rod to be checked is at the bottom of its stroke. 2. Remove oil film from surface
to be checked. Plastigage is soluble in oil.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Inspection > Page 1672
3. Place a piece of Plastigage across the entire width of the bearing shell in the bearing cap
approximately 6.35 mm (1/4 inch) off center and away
from the oil hole. In addition, suspect areas can be checked by placing Plastigage in the suspect
area.
4. Assemble the rod cap with Plastigage in place. Tighten the rod cap to the specified torque. Do
not rotate the crankshaft while assembling the cap
or the Plastigage may be smeared, giving inaccurate results.
Clearance Measurement
5. Remove the bearing cap and compare the width of the flattened Plastigage with the scale
provided on the package. Locate the band closest to the
same width. This band indicates the amount of oil clearance. Differences in readings between the
ends indicate the amount of taper present. Record all readings taken. Plastigage generally is
accompanied by two scales. One scale is in inches, the other is a metric scale. If the bearing
clearance exceeds 0.076 mm (0.003 inch) replace bearing.
NOTE: Plastigage is available in a variety of clearance ranges. Use the most appropriate range for
the specifications you are checking.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Inspection > Page 1673
Crankshaft Main Bearing: Service and Repair Fitting Bearings
CRANKSHAFT OIL CLEARANCE
Crankshaft Specification Chart
Measure Crankshaft Journal
Measure the journal outside diameter as shown in image. Refer to Crankshaft Specification Chart.
PLASTIGAGE (OIL CLEARANCE) MEASUREMENT
1. Remove oil from journal and bearing shell. 2. Install crankshaft.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft Main Bearing
> Component Information > Service and Repair > Inspection > Page 1674
Measuring Bearing Clearance With Plastigage
3. Cut plastigage to same length as width of the bearing and place it in parallel with the journal
axis. 4. Install the main bearing cap carefully and tighten the bolts to specified torque.
CAUTION: Do not rotate crankshaft or the plastigage will be smeared. 5. Carefully remove the
bearing cap and measure the width of the plastigage at the widest part using the scale on the
plastigage package. Refer to
Crankshaft Specification Chart for proper clearances. If the clearance exceeds the specified limits,
replace the main bearing(s) and if necessary, have the crankshaft machined to next undersize.
CAUTION: Do not rotate crankshaft or the Plastigage may be smeared.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications
Crankshaft: Specifications
Type .....................................................................................................................................................
...................................................... Cast Nodular Iron Bearing Type ...................................................
............................................................................................................................. Aluminum Lead
(Bimetal) Thrust Location ....................................................................................................................
............................................................................ No. 2 Bearing Connecting Rod Journal Diameter
............................................................................................................................ 53.950-53,975 mm
(2.124-2.125 inch) Main Bearing Diametrical Clearance No. 1-4
............................................................................................................ 0.011-0.059mm
(0.0043-0.0023 inch) Max. Allowable ..................................................................................................
............................................................................... 0.102 mm (0.004 inch) End Play .........................
...............................................................................................................................................
0.09-0.24 mm (0.0036-0.0095 inch) Max. Allowable ...........................................................................
...................................................................................................... 0.381 mm (0.015 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Specifications > Page 1678
Crankshaft: Description and Operation
An Access plug is located in the right inner fender shield. Remove the plug and insert the proper
size socket, extension and ratchet, when crankshaft rotation is necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation
Crankshaft: Service and Repair Removal and Installation
MAIN BEARINGS
Main Bearing Cap Identification
Bearing caps are not interchangeable and should be marked at removal to insure correct
assembly. Upper and lower bearing halves are NOT interchangeable. Lower main bearing halves
of 1, 3 and 4 are interchangeable. Upper main bearing halves of 1, 3 and 4 are interchangeable.
CRANKSHAFT MAIN JOURNALS
Measure Crankshaft Journal O.D.
The crankshaft journals should be checked for excessive wear, taper and scoring. Limits of taper or
out-of-round on any crankshaft journals should be held to 0.025 mm (0.001 inch). Journal grinding
should not exceed 0.305 mm (0.012 inch) under the standard journal diameter. Do NOT grind
thrust faces of Number 2 main bearing. Do NOT nick crank pin or bearing fillets. After grinding,
remove rough edges from crankshaft oil holes and clean out all passages.
CAUTION: With the nodular cast iron crankshafts used it is important that the final paper or cloth
polish after any journal regrind be in the same direction as normal rotation in the engine.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1681
Main Bearing Identification
Upper and lower Number 2 bearing halves are flanged to carry the crankshaft thrust loads and are
NOT interchangeable with any other bearing halves in the engine. All bearing cap bolts removed
during service procedures are to be cleaned and oiled before installation. Bearing shells are
available in standard and the following undersizes: 0.025 mm /0.001 inch) and 0.254 mm (0.010
inch). Never install an undersize bearing that will reduce clearance below specifications.
REMOVAL
1. Remove oil pan and identify bearing caps before removal.
Removing And Installing Upper Main Bearing With Special Tool C-3059
2. Remove bearing caps one at a time. Remove upper half of bearing by inserting Special Main
Bearing Tool C-3059. into the oil hole of crankshaft. 3. Slowly rotate crankshaft clockwise, forcing
out upper half of bearing shell.
INSTALLATION
NOTE: Only one main bearing should be selectively fitted while all other main bearing caps are
properly tightened.
When installing a new upper bearing shell, slightly chamfer the sharp edges from the plain side. 1.
Start bearing in place, and insert Main Bearing Tool C-3059 into oil hole of crankshaft. 2. Slowly
rotate crankshaft counterclockwise sliding the bearing into position. Remove Special Main Bearing
Tool C-3059. 3. Install each main cap and tighten bolts finger tight. 4. Tighten number 1, 3 and 4
main cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs.+ 1/4 Turn). 5. Rotate the crankshaft until number 6
piston is at TDC. 6. To ensure correct thrust bearing alignment the following procedure must be
done:
a. Move crankshaft all the way to the rear of its travel. b. then, move crankshaft all the way to the
front of its travel. c. Wedge a appropriate tool between the rear of the cylinder block and rear
crankshaft counterweight. This will hold the crankshaft in it's most
forward position.
d. Tighten the #2 Thrust Bearing cap bolts to 41 Nm + 1/4 Turn (30 ft. lbs. + 1/4 Turn). Remove the
holding tool.
7. Install oil pan. 8. Fill engine crankcase with proper oil to correct level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Crankshaft, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1682
Crankshaft: Service and Repair Service Procedures
DIAL INDICATOR METHOD
Checking Crankshaft End Play
1. Mount a dial indicator to front of engine, locating probe on nose of crankshaft. 2. Move
crankshaft all the way to the rear of its travel. 3. Zero the dial indicator.
Crankshaft Specification Chart
4. Move crankshaft all the way to the front and read the dial indicator. Refer to Crankshaft
Specification Chart.
FEELER GAUGE METHOD
1. Move crankshaft all the way to the rear of its travel using a lever inserted between a main
bearing cap and a crankshaft cheek using care not to
damage any bearing surface. Do not loosen main bearing cap.
2. Use a feeler gauge between number 2 thrust bearing and machined crankshaft surface to
determine end play. Refer to Crankshaft Specification
Chart.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Description and Operation
Engine Block Heater: Description and Operation
The engine block heater is available as an optional accessory on all models. The heater is
operated by ordinary house current (110 Volt A.C.) through a power cord located behind the
radiator grille. This provides easier engine starting and faster warm-up when vehicle is operated in
areas having extremely low temperatures. The heater is mounted in a core hole (in place of a core
hole plug) in the engine block, with the heating element immersed in coolant.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Engine Block Heater >
Component Information > Description and Operation > Page 1686
Engine Block Heater: Service and Repair
REMOVAL
1. Drain coolant from radiator and cylinder block. 2. Remove power cord plug from heater. 3.
Loosen screw in center of heater. Remove heater assembly.
INSTALLATION
1. Thoroughly clean core hole and heater seat. 2. Insert heater assembly with element loop
positioned upward. 3. With heater seated, tighten center screw securely to assure a positive seal.
4. Fill cooling system with coolant to the proper level, vent air, and inspect for leaks. Pressurize
system with Radiator Pressure Tool before looking
for leaks.
5. Install power cord plug to heater.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Expansion/Freeze Plug >
Component Information > Service and Repair
Expansion/Freeze Plug: Service and Repair
REMOVAL
Core Hole Plug Removal
Using a blunt tool such as a drift or a screwdriver and a hammer, strike the bottom edge of the cup
plug. With the cup plug rotated, grasp firmly with pliers or other suitable tool and remove plug
CAUTION: Do not drive cup plug into the casting as restricted cooling can result and cause serious
engine problems.
INSTALLATION
Thoroughly remove all rust and clean inside of cup plug hole in cylinder block or head. Be sure to
remove old sealer. Lightly coat inside of cup plug hole with sealer. Make certain the new plug is
cleaned of all oil or grease. Using proper drive plug, drive plug into hole so that the sharp edge of
the plug is at least 0.5 mm (0.020 inch.) inside the lead in chamfer. It is in not necessary to wait for
curing of the sealant. The cooling system can be refilled and the vehicle placed in service
immediately.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley
Harmonic Balancer - Crankshaft Pulley: Specifications Chrankshaft Pulley
Chrankshaft Pulley
Torque Specifications 54 Nm (40 ft.lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Crankshaft Pulley > Page 1694
Harmonic Balancer - Crankshaft Pulley: Specifications Harmonic Balancer/Vibration Damper
Crankshaft Damper Pulley to Crankshaft Bolt
.......................................................................................................................................... 54 Nm (40
ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Harmonic Balancer Crankshaft Pulley > Component Information > Specifications > Page 1695
Harmonic Balancer - Crankshaft Pulley: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. 3. Remove right wheel and
inner splash shield. 4. Remove drive belt.
Crankshaft Damper-Removal
5. Remove crankshaft pulley.
INSTALLATION
Crankshaft Damper-Installation
1. Install crankshaft pulley. 2. Install drive belt. 3. Install inner splash shield and wheel. 4. Connect
negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Specifications
Piston: Specifications
Type Material .......................................................................................................................................
.................................... Aluminum Alloy Tin Coated Clearance at Size Location
..........................................................................................................................................
0.025-0.057 mm (0.001-0.0022 inch) Weight (Standard Only)-3.3L
........................................................................................................................................ 381±5
grams (13.4394±0.1764 oz.) Weight (Standard Only)-3.8L
........................................................................................................................................ 438±5
grams (15.4501±0.1764 oz.) Pistons for Service ................................................................................
........................................................................................................... Standard Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation
Piston: Service and Repair Removal and Installation
REMOVAL
1. Disconnect negative cable from battery. 2. Remove cylinder heads and oil pan. 3. Remove top
ridge of cylinder bores with a reliable ridge reamer before removing pistons from cylinder block. Be
sure to keep tops of pistons
covered during this operation. Pistons and connecting rods must be removed from top of cylinder
block. When removing piston and connecting rod assemblies from the engine, rotate crankshaft so
that each connecting rod is centered in cylinder bore.
Identify Connecting Rod To Cylinder
4. Inspect connecting rods and connecting rod caps for cylinder identification. Identify them if
necessary.
Connecting Rod Protectors
5. Remove connecting rod cap. Install connecting rod bolt protectors on connecting rod bolts. Push
each piston and rod assembly out of cylinder
bore.
NOTE: Be careful not to nick crankshaft journals.
6. After removal, install bearing cap on the mating rod.
INSTALLING PISTON AND CONNECTING ROD ASSEMBLY
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1701
Piston Ring End Gap Position
1. Before installing pistons and connecting rod assemblies into the bore, be sure that compression
ring gaps are staggered so that neither is in line
with oil ring rail gap.
2. Before installing the ring compressor, make sure the oil ring expander ends are butted and the
rail gaps located as shown in image. 3. Lubricate the piston and rings with clean engine oil.
Position a ring compressor over the piston and rings, and tighten the compressor. Be sure
position of rings does not change during this operation.
4. Install connecting rod bolt protectors on rod bolts.
Piston-Installation
5. Rotate crankshaft so that the connecting rod journal is on the center of the cylinder bore. Insert
rod and piston into cylinder bore and guide rod
over the crankshaft journal.
6. Tap the piston down in cylinder bore, using a hammer handle. At the same time, guide
connecting rod into position on connecting rod journal.
Piston I.D. Notches
7. The notch or groove on top of piston must be pointing toward front of engine. 8. Install rod caps.
Install nuts on cleaned and oiled rod bolts and tighten nuts to 54 Nm (40 ft. lbs.) Plus 1/4 turn. 9.
Repeat procedure for each piston and rod installation.
10. Install cylinder heads and oil pan. 11. Fill engine crankcase with proper oil to correct level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1702
12. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1703
Piston: Service and Repair Fitting Pistons
PISTONS
Piston Measurements
The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90
degrees to piston pin at size location shown in image.
Checking Cylinder Bore Size
Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine
crankshaft center line shown in image.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston, Engine >
Component Information > Service and Repair > Removal and Installation > Page 1704
Refer to Cylinder Bore and Piston Specification Chart. Pistons and cylinder bores should be
measured at normal room temperature, 70°F (21°C).
RINGS
Check Gap On Piston Rings
1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
The ring gap measurement must be made with the
ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler
gauge. Refer to Piston Ring Specification Chart.
2. Check piston ring to groove clearance: Refer to Piston Ring Specification Chart.
Piston Ring Specification Chart
Piston Ring Specification Chart
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Pin, Engine >
Component Information > Specifications
Piston Pin: Specifications
Type .....................................................................................................................................................
.............. Press Fit in Rod (Serviced as an Assembly) Diameter .........................................................
..................................................................................................................... 22.88 mm
(0.9009-0.9007 inch) Length ...............................................................................................................
............................................................ 67.25-67.57 mm (2.648-2.667 inch) Clearance in Piston @
70° ........................................................................................................................................
0.006-0.019 mm (0.0002-0.0007 inch) Clearance in Rod ...................................................................
........................................................................................................................... (Interference)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications
Piston Ring: Specifications
Piston Rings
Number of Rings ..................................................................................................................................
............................................................................ 3 Compression .......................................................
..............................................................................................................................................................
2 Oil Control .........................................................................................................................................
.............................................................................. 1 Oil Ring Type .....................................................
........................................................................................................... 3-Piece, Steel Rail, Chrome
Face
Piston Ring Gap
Top & 2nd Compressing Ring
................................................................................................................................... 0.30-0.55 mm
(0.0118-0.0217 inch) Oil Control (Steel Rails)
.......................................................................................................................................... 0.25-1.00
mm ((0.0098-0.0394 inch)
Service Rings
Ring Gap-Compression
......................................................................................................................................... 0.300-0.550
mm (0.0118-0.0217 inch) Ring Gap-Oil Control
..............................................................................................................................................
0.250-1.00 mm (0.0098-0.0394 inch)
Piston Ring Side Clearance
Top & 2nd Compression Rings
............................................................................................................................. 0.030-0.095 mm
(0.0012-0.0037 inch) Oil Ring (Steel Rails
.............................................................................................................................................
0.014-0.226 mm (0.0005-0.0089 inch)
Piston Ring Width
Compression Rings
...................................................................................................................................................
1.46-1.50 mm (0.0575-0.0591 inch) Oil Ring (Steel Rails) ..................................................................
................................................................................................. 0.510 mm (0.0201 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications > Page 1711
Piston Ring: Service and Repair
PISTONS
Piston Measurements
The piston and cylinder wall must be clean and dry. Piston diameter should be measured 90
degrees to piston pin at size location shown in image.
Checking Cylinder Bore Size
Cylinder bores should be measured halfway down the cylinder bore and transverse to the engine
crankshaft center line shown in image.
Refer to Cylinder Bore and Piston Specification Chart. Pistons and cylinder bores should be
measured at normal room temperature, 70°F (21°C).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Block Assembly > Piston Ring, Engine >
Component Information > Specifications > Page 1712
RINGS
Check Gap On Piston Rings
1. Wipe cylinder bore clean. Insert ring and push down with piston to ensure it is square in bore.
The ring gap measurement must be made with the
ring positioning at least 12 mm (0.50 inch) from bottom of cylinder bore. Check gap with feeler
gauge. Refer to Piston Ring Specification Chart.
2. Check piston ring to groove clearance: Refer to Piston Ring Specification Chart.
Piston Ring Specification Chart
Piston Ring Specification Chart
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
This engine is equipped with hydraulic valve lifters and are not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Fuel Pressure Release >
System Information > Service and Repair > CNG Engine > Page 1721
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications
Rocker Arm Assembly: Specifications
Rocker Shaft Bracket Bolts ..................................................................................................................
............................................... 28 Nm (250 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Rocker Arm Assembly >
Component Information > Specifications > Page 1725
Rocker Arm Assembly: Service and Repair
REMOVAL
1. Remove upper intake manifold assembly. 2. Disconnect spark plug wires by pulling on the boot
straight out in line with plug. 3. Disconnect closed ventilation system. 4. Remove cylinder head
cover and gasket. 5. Remove four rocker shaft bolts and retainers. 6. Remove rocker arms and
shaft assembly.
Rocker Arm Location Left Bank
7. If rocker arm assemblies are disassembled for cleaning or replacement. Assemble rocker arms
in their original position. Refer to image for rocker
arm for positioning on the shaft.
INSTALLATION
1. Install rocker arm and shaft assemblies with the stamped steel retainers in the four positions,
tighten to 28 Nm (250 inch lbs.).
CAUTION: The rocker arm shaft should be torqued down slowly, starting with the center bolts.
Allow 20 minutes tappet bleed down time after installation of the rocker shafts before engine
operation.
2. Clean cylinder head cover gasket surface. Inspect cover for distortion and straighten if
necessary. 3. Clean head rail if necessary. Install a new gasket and tighten cylinder head cover
fasteners to 12 Nm (105 inch lbs.). 4. Install closed crankcase ventilation system. 5. Install spark
plug wires. 6. Install upper intake manifold assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Specifications
Valve Cover: Specifications
Bolts
Non-isolated cylinder head cover
.............................................................................................................................................. 12 Nm
(105 inch lbs.) Isolated cylinder head cover
........................................................................................................................................................ 10
Nm (90 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Cover >
Component Information > Specifications > Page 1729
Valve Cover: Service and Repair
REMOVAL
Cylinder Head Cover-Isolated Type
NOTE: The cylinder head cover can be either an isolated type or a non-isolated type.
Front Cylinder Head Cover
1. Disconnect ignition cables from spark plugs. 2. Disconnect crankcase vent hose from cylinder
head cover. 3. Remove front cylinder head cover bolts. 4. Remove cylinder head cover and gasket.
Rear Cylinder Head Cover
1. Disconnect negative cable from battery. 2. Remove Wiper Unit. Refer to Windshield Wipers and
Washers for procedure. 3. Remove intake manifold upper plenum. 4. Disconnect PCV hose from
cylinder head cover. 5. Remove rear cylinder head cover bolts 6. Remove cylinder head cover and
gasket.
INSTALLATION
Front Cylinder Head Cover
1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness.
Replace gasket as necessary. 2. Install cylinder head cover and bolts. 3. Tighten cylinder head
cover bolts to the following specifications:
- Non-isolated cylinder head cover to 12 Nm (105 inch lbs.).
- Isolated cylinder head cover to 10 Nm (90 inch lbs.).
4. Connect crankcase vent hose. 5. Connect ignition cables to spark plugs.
Rear Cylinder Head Cover
1. Clean cylinder head and cover mating surfaces. Inspect cylinder head cover surface for flatness.
Replace gasket as necessary. 2. Install cylinder head cover and bolts. 3. Tighten cylinder head
cover bolts to the following specifications:
- Non-isolated cylinder head cover to 12 Nm (105 inch lbs.).
- Isolated cylinder head cover to 10 Nm (90 inch lbs.).
4. Connect PCV hose from cylinder head cover. 5. Install intake manifold upper plenum. 6. Install
Wiper Unit. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Guide >
Component Information > Specifications
Valve Guide: Specifications
Type .....................................................................................................................................................
............................................. Powdered Metal Inserts Guide Bore Diameter
...............................................................................................................................................
7.975-8.00 mm (0.314 mm-0.315 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Seat > Component
Information > Specifications
Valve Seat: Specifications
Angle-Intake and Exhaust ...................................................................................................................
..................................................................... 45-45.5°
Runout (Max.) ......................................................................................................................................
........................................... 0.0762 mm (0.003 inch) Width (Finish)-Intake
........................................................................................................................................................
1.75-2.25 mm (0.069-0.088 inch) Width (Finish)-Exhaust
.....................................................................................................................................................
1.50-2.00 mm (0.057-0.078 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Specifications
Valve Spring: Specifications
Free Length (Approximately)
..............................................................................................................................................................
48.5 mm (1.909 inch) Wire Diameter ...................................................................................................
.................................................................................. 4.75 mm (0.187 inch) Number of Calls .............
..............................................................................................................................................................
..................................... 6.8 Spring Tension (Valve Closed)
........................................................................................................................................................
95-100 lbs. @ 1.57 inch Spring Tension (Valve Open)
......................................................................................................................................................
207-229 lbs. @ 1.169 inch Installed Height (Spring Seat to Bottom of Retainer)
....................................................................................................... 41.2-42.7 mm (1.622-1.681 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head Off
Valve Spring: Service and Repair Cylinder Head Off
REMOVAL
Compress Valve Springs With Special Tool C-3422-B With Adapter 6412
1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412 as shown in image. 2. Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure
installation in original location.
INSTALLATION
1. Coat valve stems with clean engine oil and insert them in cylinder head.
Checking Valve Installed Height
2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve
tip to give 49.541 to 51.271 mm (1.950 to 2.018
inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent sea:. damage when the valve is installed.
Valve Seal And Spring-Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head Off > Page 1741
3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over
valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring
Compressor Tool C-3422-B, with adapter 6412 install locks and release tool. If valves and/or seats
are
reground, measure the installed height of springs dimension B. make sure measurements are
taken from top of spring seat to the bottom surface of spring retainer. If height is greater than
1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore to bring
spring height back to normal 1-17/32 to 1-19/32 inch (39.1 to 40.6 mm).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve Spring >
Component Information > Service and Repair > Cylinder Head Off > Page 1742
Valve Spring: Service and Repair Cylinder Head On
1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect
negative cable from battery. 3. Remove air cleaner cover and hose assembly. 4. Remove upper
intake manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove electrical connector
from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw,
turn engine so the number 1 piston is at Top Dead Center on the
compression stroke.
8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be
disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1
spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to
hold valves in place while servicing components.
10. Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and
valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve
guide using the valve stem as guide. Do Not Force seal against
top of guide. When installing the valve retainer locks, compress the spring only enough to install
the locks.
CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6.
Make sure piston in cylinder is at TDC on the valve
spring that is being covered.
13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly
and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14
Nm (120 inch lbs.) and electrical connector to ignition coils. 16. Install Intake Manifold. 17. Connect
negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Specifications
Valve: Specifications
INTAKE VALVE
Face Angle ..........................................................................................................................................
........................................................................... 44.5°
Head Diameter ....................................................................................................................................
...................................................... 45.5 mm (1.79 in.) Length (Overall)
......................................................................................................................................................
127.005-128.036 mm (5.000-5.041 in.) Minimum Valve Length After Tip Grinding
........................................................................................................................................... 124.892
(4.916 in.) Lift (Zero Lash) ...................................................................................................................
................................................................. 10.16 mm (0.400 in.) Stem Diameter (Standard)
..............................................................................................................................................
7.935-7.953 mm (0.312-0.313 mm) Valve Tip Height (From Cylinder Head Surface)
...................................................................................................... 49.541-512.271 mm (1.950-2.018
in.) Stem-to-Guide Clearance
.................................................................................................................................................
0.025-0.095 mm (0.001-0.003 in.) Max. Allowable (Rocking Method)
......................................................................................................................................................
0.247 mm (0.010 in.) Valves for Service (Oversize Stem Diameters)
- Standard
- 0.015 mm (0.005 in.)
- 0.040 mm (0.015 in.)
- 0.080 mm (0.030 in.)
EXHAUST VALVE
Face Angle ..........................................................................................................................................
.............................................................................. 45°
Head Diameter ....................................................................................................................................
.................................................... 37.5 mm (1.476 in.) Length Overall
.........................................................................................................................................................
127.825-128.465 mm (5.032-5.048 in.) Minimum Valve Length After Tip Grinding
.................................................................................................................................... 125.512 mm
(4.941 in.) Lift (Zero Lash) ...................................................................................................................
................................................................. 10.16 mm (0.040 in.) Valve Tip Height (From Cylinder
Head Surface) ........................................................................................................ 49.541-51.271
mm (1.950-2.018 in.) Stem Diameter (Standard)
............................................................................................................................................
7.906-7.924 mm (0.3112-0.3119 in.) Stem to Guide Clearance
.................................................................................................................................................
0.051-0.175 mm (0.002-0.006 in.) Max. Allowable (Rocking Method)
......................................................................................................................................................
0.414 mm (0.016 in.) Valves for Service (Oversize Stem Diameters)
- Standard
- 0.015 mm (0.005 in.)
- 0.040 mm (0.015 in.)
- 0.080 mm (0.030 in.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation
Valve: Service and Repair Removal and Installation
REMOVAL
Compress Valve Springs With Special Tool C-3422-B With Adapter 6412
1. With cylinder head removed, compress valve springs using Valve Spring Compressor Tool
C-3422-B with adapter 6412 as shown in image. 2. Remove valve retaining locks, valve spring
retainers, valve stem seals and valve springs. 3. Before removing valves, remove any burrs from
valve stem lock grooves to prevent damage to the valve guides. Identify valves to insure
installation in original location.
INSTALLATION
1. Coat valve stems with clean engine oil and insert them in cylinder head.
Checking Valve Installed Height
2. Check valve tip to spring seat dimensions A after grinding the valve seats or faces. Grind valve
tip to give 49.541 to 51.271 mm (1.950 to 2.018
inch) over spring seat when installed in the head. Check valve tip for scoring, if necessary, the tip
chamfer should be reground to prevent sea:. damage when the valve is installed.
Valve Seal And Spring-Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1748
3. Install valve spring seat spacer on head. 4. Install new cup seals on all valve stems and over
valve guides. Install valve springs and valve retainers. 5. Compress valve springs with Valve Spring
Compressor Tool C-3422-B, with adapter 6412 install locks and release tool. If valves and/or seats
are
reground, measure the installed height of springs dimension B. make sure measurements are
taken from top of spring seat to the bottom surface of spring retainer. If height is greater than
1-19/32 inches, (40.6 mm), install a 1/32 inch (0.794 mm) spacer in head counterbore to bring
spring height back to normal 1-17/32 to 1-19/32 inch (39.1 to 40.6 mm).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1749
Valve: Service and Repair Valve Service
SERVICE RECONDITION Valve Inspection
1. Clean valves thoroughly and discard burned, warped and cracked valves.
Valve Specification Chart
2. Measure valve stems for wear. Refer to Valve Dimension Chart.
CAUTION: Valve stems are chrome plated and should not be polished.
3. Remove carbon and varnish deposits from inside of valve guides with a reliable guide cleaner. 4.
Measure valve stem guide clearance as follows:
a. Install valve into cylinder head so it is 14 mm (0.551 inch) off the valve seat. A small piece of
hose may be used to hold valve in place.
Measuring Valve Guide Wear
b. Attach dial indicator Tool C-3339 to cylinder head and set it at right angle of valve stem being
measured.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1750
Valve Seats
5. Move valve to and from the indicator. Refer to Valve Guide Specification Chart. 6. Ream the
guides for valves with oversized stems if dial indicator reading is excessive or if the stems are
scuffed or scored. 7. Service valves with oversize stems and over size seals are available in 0.15
mm (0.006 inch), 0.40 mm, (0.015 inch) and 0.80 mm (0.030 inch)
oversize.
NOTE: Oversize seals must be used with oversize valves.
8. Refer to Valve Guide Specification Chart for reamer size to accommodate the oversize valve
stems. 9. Slowly turn reamer by hand and clean guide thoroughly before installing new valve. Do
not attempt to rean1 the valve guides from standard
directly to 0.80 mm (0.030 inch) Use step procedure of 0.15 mm (0.005 inch), 0.40 mm (0.015 inch)
and 0.80 mm (0.030 inch) so the valve guides may be reamed true in relation to the valve seat.
After reaming guides, the seat runout should be measured and resurfaced if necessary. See
Refacing Valves and Valve Seats.
Valve Guides
NOTE: Replace cylinder head if guide does not clean up with 0.80 mm (0.030 inch) oversize
reamer, or if guide is loose in cylinder head.
Refacing Valves And Valve Seats
Valve Seats
The intake and exhaust valves have a 44-1/2 to 45 degree face angle. The valve seats have a 45
to 45 1/2 degree face angle. The valve face and valve seat angles are shown in image.
Valves
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1751
Valve Specification Chart
1. Inspect the remaining margin after the valves are refaced Refer to Valve Dimension Chart.
Valve Seats
Refacing Valve Seats
CAUTION: Remove metal from valve seat only. Do not remove metal from cylinder head.
1. When refacing valve seats, it is important that the correct size valve guide pilot be used for
reseating stones. A true and complete surface must be
obtained.
2. Measure the concentricity of valve seat using dial indicator. Total runout should not exceed
0.051 mm (0.002 inch) total indicator reading. 3. Inspect the valve seat using Prussian blue to
determine where the valve contacts the seat. To do this, coat valve seat LIGHTLY with Prussian
blue
then set valve in place. Rotate the valve with light pressure. If the blue is transferred to the center
of valve face, contact is satisfactory. If the blue is transferred to top edge of valve face, lower valve
seat with a 15 degree stone. If the blue is transferred to the bottom edge of valve face raise valve
seat with a 65 degrees stone.
NOTE: Valve seats which are worn or burned can be reworked, provided that correct angle and
seat width are maintained. Otherwise cylinder head must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Cylinder Head Assembly > Valve, Intake/Exhaust >
Component Information > Service and Repair > Removal and Installation > Page 1752
Valve Guide Specification Chart
4. When seat is properly positioned the width of intake seats should be 1.75 to 2.25 mm (0.059 to
0.088 inch) The width of the exhaust seats should
be 1.50 to 2.00 mm (0.059 to 0.078 inch).
Checking Valve Installed Height
5. Check the valve spring installed height after refacing the valve and seat.
Testing Valve Springs
Testing Valve Springs
Whenever valves have been removed for inspection, reconditioning or replacement, valve springs
should be tested. As an example; the compression length of the spring to be tested is 33.34 mm (1
5/16 inches). Turn table of Tool C-647 until surface is in line with the 33.34 mm (1 5/16 inch) mark
on the threaded stud and the zero mark on the front. Place spring over stud on the table and lift
compressing lever to set tone device. Pull on torque wrench until ping is heard. Take reading on
torque wrench at this instant. Multiply this reading by two. This will give the spring load at test
length. Fractional measurements are indicated on the table for finer adjustments. Refer to
specifications to obtain specified height and allowable tensions. Discard the springs that do not
meet specifications.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99
> A/C Compressor - Locks Up At Low Mileage
Drive Belt: Customer Interest A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 24-15-99 > Jul > 99
> A/C Compressor - Locks Up At Low Mileage > Page 1762
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist
Drive Belt: Customer Interest Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1767
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1768
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Customer Interest for Drive Belt: > 07-02-99 > Jun > 99
> Serpentine Belt - Loss of Power Steering Assist > Page 1769
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage
Drive Belt: All Technical Service Bulletins A/C Compressor - Locks Up At Low Mileage
Number: 24-15-99
Group: Heating & A/C
Date: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-07-98 REV. A, DATED
AUGUST. 28, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE
1998 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Compressor Lock-Up At Low Mileage
OVERVIEW: This bulletin involves determining the extent of A/C compressor lock-up and either
working the compressor loose or replacing it.
MODELS:
1998 - **2000** (NS) Town & Country/Caravan/Voyager 1998 - **2000** (GS) Chrysler Voyager
(International Market) 1998 - **2000** (PL) Neon
NOTE:
THE A/C SYSTEM SHOULD BE OPERATED FOR A MINIMUM OF 5 MINUTES IN THE FRESH
AIR A/C, HIGH BLOWER MODE, WITH THE ENGINE AT IDLE, PRIOR TO TAKING A VEHICLE
OUT OF OPERATION OR STORING IT FOR MORE THAN TWO WEEKS TO INSURE
ADEQUATE OIL FLOW BACK TO THE A/C COMPRESSOR.
SYMPTOM/CONDITION:
The A/C compressor may lock-up, causing the drive belt to slip in the A/C clutch pulley, producing
a squealing noise at initial start-up. This "temporary" lock-up DOES NOT NECESSARILY MEAN
THE COMPRESSOR HAS FAILED.
With the close internal clearances of a compressor operating in an R134A system, it is possible to
experience a temporary lock-up of the piston shoes on the swash plate. The longer the A/C system
is inactive, the more likely the lock-up condition is to occur.
This condition is the result of normal refrigerant movement within the A/C system caused by
temperature differences between the various components (evaporator, condenser, compressor)
that "washes" the oil out of the compressor.
DIAGNOSIS: Start the vehicle and run at idle. Turn on the A/C system and listen for the drive belt
to squeal. Immediately turn off the A/C system if squealing is heard. If the squeal stops when the
A/C system is turned off perform the Repair Procedure.
REPAIR PROCEDURE:
This bulletin involves determining the extent of A/C compressor lock-up and either working the
compressor loose or replacing it.
Before assuming the A/C compressor has failed and must be replaced, the following steps should
be taken.
1. With an appropriate sized oil filter removal tool or strap wrench, grasp the outer diameter of the
A/C compressor clutch hub that houses the rubber donut. While facing the compressor, try to rotate
the hub clockwise, then counterclockwise. If the hub rotates go to step 2. If the hub will not rotate
the compressor is internally damaged and must be replaced, skip to step 7.
2. Turn the hub clockwise five complete revolutions and remove the tool.
3. Start the vehicle, turn on the A/C system, and run at idle.
4. Observe the A/C compressor and system for normal operation for both cool-down and noise
level standpoints.
5. If performance is acceptable (use the A/C Performance Temperatures chart in diagnosis and
testing portion section 24 of the appropriate Service Manual as a guideline), allow the A/C system
to operate at idle for 5 minutes.
6. If acceptable performance continues throughout the five minutes, the compressor does not need
to be replaced, skip to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
24-15-99 > Jul > 99 > A/C Compressor - Locks Up At Low Mileage > Page 1775
7. If performance is not up to acceptable levels, or the compressor is internally damaged, use the
procedure outlined in the appropriate Service Manual to replace the A/C compressor.
8. Inspect the drive belt for damage, replace it if necessary.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 24-10-01-92 Repair Compressor 0.3 Hrs.
24-10-01-93 Replace Compressor 1.2 Hrs.
FAILURE CODE: 07 - Binds, Sticks or Seized
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Drive Belt: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1780
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1781
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Drive Belt: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1782
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1783
Drive Belt: Specifications
Belt Tension Chart
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1784
Drive Belt: Description and Operation
The accessory drive system utilizes two different style of drive belts. The conventional V-belt and
the Poly-V belt are used to drive the generator, air conditioning compressor, power steering pump
and water pump. Satisfactory performance of these belts depends on belt condition and proper belt
tension. Belt tensioning should be performed with the aid of a Burroughs gauge Special Tool
C-4162. Because of space limitations in the engine compartment, the use of the gauge may be
restricted. Raise the vehicle on a hoist and then remove the splash shield to gain access to the
drive belts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1785
Accessory Drive Belt
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Technical Service Bulletins > Page 1786
Drive Belt: Adjustments
Satisfactory performance of the belt driven accessories depends on proper belt tension. Belt
tensioning should be performed with the aid of a Burroughs gauge Special Tool C-4162. Because
of space limitations in the engine compartment, the use of the gauge may be restricted. Raise the
vehicle on a hoist and the remove the splash shield to gain access to the drive belts.
Use belt tensioning Special Tool Kit C-4162 for:
CAUTION: The Burroughs gauge for the Poly-V belt is not to be used on the V-belt. These gauges
are not interchangeable.
- For conventional V-belts affix the Burroughs gauge (Special Tool C-4162) to the belt. Adjust the
belt tension for New or Used belt as prescribed in the Belt Tension Chart.
- For a Poly-V belt affix the Poly-V Burroughs gauge to the belt and then apply specified tension to
the belt as prescribed in the Belt Tension Chart.
Belt Tension Chart
Adjust belt tension for a New or Used belt as prescribed in the Belt Tension Chart.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation
Drive Belt: Service and Repair Removal and Installation
A/C Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install.
Alternator Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1789
3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install.
Power Steering Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
3. Release tension by rotating the tensioner clockwise. 4. Reverse above procedure to install.
Water Pump Belt
REMOVE/INSTALL
GENERATOR, POWER STEERING PUMP, AIR CONDITIONING COMPRESSOR AND WATER
PUMP DRIVE BELT The Poly-V Drive belt is provided with a dynamic tensioner to maintain proper
belt tension. To remove or install this belt. 1. Raise vehicle on hoist. 2. Remove right front splash
shield.
Accessory Drive Belt
3. Release tension by rotating the tensioner clockwise.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1790
4. Reverse above procedure to install.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Drive Belt > Component Information > Service and Repair > Removal and Installation > Page 1791
Drive Belt: Service and Repair Cleaning and Inspection
Serpentine Drive Belt Wear Patterns
When inspecting serpentine drive belts, small cracks that run across the ribbed surface of the belt
from rib to rib, are considered normal these are not reasons to replace the belt. However, cracks
running along the rib (not across) are not normal. Any belt with cracks running along the rib must
be replaced. Also replace the belt if it has excessive wear, frayed cords or severe glazing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Adjustments
Engine Mount: Adjustments
1. Remove the load on the engine motor mounts by carefully supporting the engine and
transmission assembly with a floor jack. 2. Loosen the right engine mount insulator vertical fastener
and the fore and aft fasteners, and the front engine mount bracket to front crossmember
screws.
3. Pry the engine right or left as required to achieve the proper drive shaft assembly length. 4.
Tighten engine mounts and fasteners in the following order:
a. Right engine mount insulator vertical bolts to 102 Nm (75 ft. lbs.) and the fore and aft bolts to
150 Nm (110 ft. lbs.). b. Front engine mount screws to 54 Nm (40 ft. lbs.) the clearance between
the snubbers and the engine should be 2 mm (0.078 inch.) each side. c. Left engine mount through
bolt to 75 Nm (55 ft. lbs.).
5. Recheck driveshaft length.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount
Engine Mount: Service and Repair Front Mount
REMOVAL
1. Support the engine and transmission assembly with a floor jack so it will not rotate.
Engine Mounting-Front
2. Remove the front engine mount through bolt from the insulator and front crossmember mounting
bracket. 3. Remove six screws from air dam to allow access to the front mount screws. 4. Remove
the front engine mount screws and remove the insulator assembly. 5. Remove the front mounting
bracket, if necessary.
INSTALLATION
1. Reverse removal procedure for installation and tighten fasteners in this order:
a. Tighten bolts 2,3, and 4 to 108 Nm (80 ft. lbs.). b. Tighten bolts 1 and 5 to 54 Nm (40 ft. lbs.).
2. Engine mount adjustment, Refer to Engine Mount Insulator Adjustment. 3. Install six screws to
air dam and tighten to 12 Nm (105 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1797
Engine Mount: Service and Repair Left Mount
REMOVAL
1. Raise vehicle on hoist and remove left front wheel. 2. Support the transmission with a
transmission jack. 3. Remove the insulator through bolt from the mount. 4. Remove the
transmission mount fasteners and remove mount.
INSTALLATION
1. Reverse removal procedure for installation. 2. Tighten mount to transmission bolts to 55 Nm (40
ft. lbs.)
Engine Mounting-Left
3. Tighten through bolt to 75 Nm (55 ft. lbs.). 4. Engine mount adjustment, Refer to Engine Mount
Insulator Adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1798
Engine Mount: Service and Repair Rear Mount
REMOVAL
1. Raise vehicle on hoist. 2. Support the transmission with a transmission jack so it will not rotate.
3. Remove the insulator through bolt from the mount and rear suspension crossmember. 4.
Remove the four transmission mount fasteners and remove the mount.
INSTALLATION
Engine Mounting-Rear
1. Reverse the removal procedure for installation. Tighten through bolt to 75 Nm (55 ft. lbs.)
Engine Mount Rubber Insulator
Insulator location on (right side) is adjustable to allow right/left drive train adjustment in relation to
drive shaft assembly length. Check and reposition right engine mount insulator. See Adjustments.
Adjust drive train position, if required, for the following conditions: a. Drive shaft distress. See
Suspension and Driveshafts. b. Any front end structural damage (after repair). c. Insulator
replacement.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Engine Mount > Component Information > Service and Repair > Front Mount > Page 1799
Engine Mount: Service and Repair Right Mount
REMOVAL
NOTE: Right mount should only be serviced as an assembly to prevent noise, vibration and
harshness concerns.
1. Remove the purge duty solenoid and wiring harness from engine mount.
Engine Mount-Right
2. Remove the two right engine mount insulator vertical fasteners and loosen the horizontal
fastener, Do Not remove the large nut on the end of the
core from frame rail.
3. Remove the load on the engine motor mounts by carefully supporting the engine and
transmission assembly with a floor jack. 4. Remove the vertical and horizontal fasteners from the
engine side bracket. Remove the engine mount assembly
INSTALLATION
1. Reverse removal procedure for installation. Tighten assembly in the following order:
a. Engine mount to rail fasteners to 68 Nm (50 ft. lbs.). b. The vertical engine fastener to 102 Nm
(75 ft. lbs.) c. The horizontal fastener to 150 Nm (111 ft. lbs.).
2. Install the purge duty solenoid and wiring harness to the engine mount. 3. Engine mount
adjustment, Refer to Engine Mount Insulator Adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun >
99 > Serpentine Belt - Loss of Power Steering Assist
Idler Pulley: Customer Interest Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun >
99 > Serpentine Belt - Loss of Power Steering Assist > Page 1808
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun >
99 > Serpentine Belt - Loss of Power Steering Assist > Page 1809
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > Customer Interest for Idler Pulley: > 07-02-99 > Jun >
99 > Serpentine Belt - Loss of Power Steering Assist > Page 1810
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist
Idler Pulley: All Technical Service Bulletins Serpentine Belt - Loss of Power Steering Assist
Number: 07-02-99
Group: Cooling
Date: June 4, 1999
SUBJECT: Serpentine Belt Slips Off Idler Pulley
OVERVIEW: This bulletin involves replacing the bracket that the idler pulley attaches to.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Loss of power steering assist and occurs when driving through deep
snow or standing water.
Snow or rain can enter the engine compartment from underneath the vehicle and force the
serpentine belt oft of the idler pulley.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1816
DIAGNOSIS: Visually inspect the serpentine belt and idler pulley to determine it mis-alignment
exists (If the serpentine belt is off the pulleys install the serpentine belt). Start the engine and let it
run for one minute before checking alignment). The belt should be approximately 2mm (0.08 in.)
from the inboard edge of the idler pulley (Figure 1) when alignment is correct and this bulletin does
not apply. If the belt and pulley appear as in Figure 2, perform the Repair Procedure.
PARTS REQUIRED:
1 04612412 Bracket, Engine Mount
AR (1) 04861322 Belt, Serpentine
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1817
1. Remove the serpentine belt from around the idler pulley by rotating the tensioner clockwise
(Figure 3).
2. Remove the purge duty cycle solenoid and wiring harness from the right side engine mount.
3. Remove the two right side engine mount insulator vertical fasteners and loosen the horizontal
fastener. DO NOT remove the large nut in the center of the core of the insulator (Figure 4),
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Drive Belts, Mounts, Brackets and Accessories >
Idler Pulley > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Idler Pulley: >
07-02-99 > Jun > 99 > Serpentine Belt - Loss of Power Steering Assist > Page 1818
4. Remove the load on the engine mount by carefully supporting the engine with a floor jack.
5. Remove the vertical and horizontal fasteners from the engine side bracket. Remove the engine
mount assembly.
6. Remove the idler pulley from the engine mounting bracket. (Figure 3).
7. Remove the engine mounting bracket
8. Install a new engine mounting bracket. Torque the fasteners to 40-68 Nm (30-50 ft lbs.).
9. Install the idler pulley to the engine mounting bracket. Torque the fastener to 40-68 Nm (30-50 ft
lbs.)
10. Properly route and position a serpentine belt onto all pulleys except the idler pulley (Use a new
belt if there is any evidence of damage to the original one).
11. Rotate the belt tensioner clockwise until the belt can be installed onto the idler pulley. Slowly
release the belt tensioner.
12. Install the engine mount; torque the assembly in the following order, engine mount to rail
fasteners 68 Nm (50 ft. lbs.), vertical fastener 102 Nm (75 ft. lbs.), and horizontal fastener 150 Nm
(111 ft. lbs.).
13. Install the purge duty cycle solenoid to the engine mount.
14. Start the vehicle and let it run for one minute then turn the engine off.
15. Verify the serpentine belt is properly aligned (Figure 1).
16. If the serpentine belt has moved toward the outboard edge of the idler pulley, further diagnosis
will be required.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 07-20-20-96 0.7 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications
Engine Oil Pressure: Specifications
Minimum Pressure at Idle (Engine Fully Warmed Up)*
............................................................................................................................. 34.47 kPa (5 psi) At
3000 rpm .............................................................................................................................................
....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting
...........................................................................................................................................................
62-103 kPa (9-15 psi) Oil Filter Type ...................................................................................................
..................................................................................................... Full Flow Oil Pressure Switch
Actuating Pressure (Min)
........................................................................................................................................ 14-28 kPa
(2-4 psi)
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil Pressure >
Component Information > Specifications > Page 1823
Engine Oil Pressure: Testing and Inspection
Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5
psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM.
Checking Oil Pump Pressure
1. Remove pressure sending unit and install oil pressure gauge.
CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM.
2. Warm engine at high idle until thermostat opens.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications
Engine Oil: Capacity Specifications
Engine Oil
With Filter Change ...............................................................................................................................
............................................................. 4.3L (4.5 Qt)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Capacity Specifications > Page 1828
Engine Oil: Fluid Type Specifications
The content of this article reflects changes called for in TSB 26-11-97.
Engine Oil
API Classification .................................................................................................................................
........................................... SH or SH/CD or Above Above 0°F (-18°C) .............................................
.......................................................................................................................................................
10W-30 Below 32°F (0°C) ...................................................................................................................
.................................................................................... 5W-30
If vehicle operates on E-85 fuel either full or part-time, use only Mopar Flexible Fuel 5w-30 engine
oil or an equivalent that meets Chrysler standard MS-9214. SAE 5w-30 engine oil is preferred for
use in Flexible Fuel engines.
CAUTION: If Flexible Fuel engine oil is not used when using E-85 fuel, engine wear or damage
may result.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1829
Engine Oil: Description and Operation
WARNING: NEW OR USED ENGINE OIL CAN BE IRRITATING TO THE SKIN. AVOID
PROLONGED OR REPEATED SKIN CONTACT WITH ENGINE OIL. CONTAMINANTS IN USED
ENGINE OIL, CAUSED BY INTERNAL COMBUSTION, CAN BE HAZARDOUS TO YOUR
HEALTH. THOROUGHLY WASH EXPOSED SKIN WITH SOAP AND WATER. DO NOT WASH
SKIN WITH GASOLINE, DIESEL FUEL, THINNER, OR SOLVENTS, HEALTH PROBLEMS CAN
RESULT. DO NOT POLLUTE, DISPOSE OF USED ENGINE OIL PROPERLY. CONTACT YOUR
DEALER OR GOVERNMENT AGENCY FOR LOCATION OF COLLECTION CENTER IN YOUR
AREA.
ENGINE OIL SPECIFICATION
CAUTION: Do not use non-detergent or straight mineral oil when adding or changing crankcase
lubricant. Engine failure can result.
API SERVICE GRADE CERTIFIED
Use an engine oil that is API Service Grade Certified. MOPAR provides engine oils that conforms
to this service grade.
SAE VISCOSITY
Temperature/Engine Oil Viscosity
An SAE viscosity grade is used to specify the viscosity of engine oil. Use only, engine oils with
multiple viscosities such as 5W-30 or 10W-30. These are specified with a dual SAE viscosity grade
which indicates the cold-to-hot temperature viscosity range. Select an engine oil that is best suited
to your particular temperature range and variation.
ENERGY CONSERVING OIL
An Energy Conserving type oil is recommended for gasoline engines. They are designated as
either ENERGY CONSERVING or ENERGY CONSERVING II.
CONTAINER IDENTIFICATION
Engine Oil Container Standard Notations
Standard engine oil identification notations have been adopted to aid in the proper selection of
engine oil. The identifying notations are located on the label of engine oil plastic bottles and the top
of engine oil cans.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1830
Engine Oil: Testing and Inspection
To assure proper engine lubrication, the engine oil must be maintained at the correct level. Check
the oil level at regular intervals, such as every fuel stop. The best time to check the oil level is
about 5 minutes after a fully warmed-up engine is shut off, or before starting the vehicle after it has
sat overnight.
3.0L Engine Dipstick
Checking the oil while the vehicle is on level ground, will improve the accuracy of the oil level
readings. Maintain the oil level between the MIN and MAX markings on the dipstick. Adding one
quart of oil when the reading is at the MIN mark will result in a MAX reading on these engines.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Engine Oil > Component
Information > Specifications > Page 1831
Engine Oil: Service and Repair
ENGINE OIL CHANGE
Change engine oil at mileage and time intervals described in the Maintenance Schedule.
TO CHANGE ENGINE OIL
Run engine until achieving normal operating temperature. 1. Position the vehicle on a level surface
and turn engine off. 2. Hoist and support vehicle on safety stands. 3. Remove oil fill cap. 4. Place a
suitable drain pan under crankcase drain. 5. Remove drain plug from crankcase and allow oil to
drain into pan. Inspect drain plug threads for stretching or other damage. Replace drain plug
and gasket if damaged.
6. Install drain plug in crankcase. 7. Lower vehicle and fill crankcase with specified type and
amount of engine oil described in this section. 8. Install oil fill cap. 9. Start engine and inspect for
leaks.
10. Stop engine and inspect oil level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Specifications
Oil Filter: Specifications
Oil Filter Attaching Nipple ....................................................................................................................
................................................... 41 Nm (30 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Filter, Engine > Component
Information > Specifications > Page 1835
Oil Filter: Service and Repair
Oil Filter
CAUTION: When servicing the oil filter avoid deforming the filter can by installing the remove/install
tool band strap against the can-to-base lock seam. The lock seam joining the can to the base is
reinforced by the base plate.
1. Using Tool C-4065, turn filter counterclockwise to remove from base. Properly discard filter. 2.
Wipe base clean, then inspect gasket contact surface. 3. Lubricate gasket of new filter with clean
engine oil. 4. Install new filter until gasket contacts base. Tighten filter 1 turn or 20 Nm (15 ft. lbs.).
Use filter wrench if necessary. 5. Start engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Specifications
Oil Pan: Specifications
Bolts .....................................................................................................................................................
............................................... 12 Nm (105 inch lbs.) Drain Plug .........................................................
........................................................................................................................................ 27 Nm (20 ft.
lbs.) Level Sensor Plug ........................................................................................................................
.............................................................. 41 Nm (30 ft. lbs. Pressure Gauge Sending Unit .................
................................................................................................................................................. 7 Nm
(60 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation
Oil Pan: Service and Repair Removal and Installation
REMOVAL
1. Disconnect negative cable from battery and remove engine oil dipstick. 2. Raise vehicle on hoist
and drain engine oil. 3. Remove bending brace to transaxle attaching bolt. 4. Remove bolts
attaching dust cover to transaxle housing. Lower dust cover to gain access to oil pan bolts. 5.
Remove oil pan screws and remove oil pan.
INSTALLATION
Oil Pan Sealing
1. Clean surfaces and apply a 1/8 inch bead of Mopar (R) Silicone Rubber Adhesive Sealant or
equivalent, at the parting line of the chain case cover
and the rear seal retainer.
Oil Pan Gasket Installation
2. Use a new pan gasket. 3. Install pan and tighten screws to 12 Nm (105 inch lbs.). 4. Install dust
shield and bending brace to transaxle housing. 5. Lower vehicle and install oil dipstick. 6. Connect
negative cable to battery. 7. Fill crankcase with oil to proper level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pan, Engine > Component
Information > Service and Repair > Removal and Installation > Page 1841
Oil Pan: Service and Repair Cleaning and Inspection
1. Clean oil pan in solvent and wipe dry with a clean cloth. Clean all gasket material from mounting
surfaces of pan and block. 2. Inspect oil drain plug and plug hole for stripped or damaged threads
and repair as necessary. Install a new drain plug gasket. Tighten to 27 Nm (20
ft. lbs.).
3. Inspect oil pan mounting flange for bends or distortion. Straighten flange if necessary. 4. Clean
oil screen and pipe in clean solvent. Inspect condition of screen.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pressure Sender >
Component Information > Locations
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications
Engine Oil Pressure: Specifications
Minimum Pressure at Idle (Engine Fully Warmed Up)*
............................................................................................................................. 34.47 kPa (5 psi) At
3000 rpm .............................................................................................................................................
....................................... 205-551 kPa (30-80 psi) Oil Filter Bypass Valve Setting
...........................................................................................................................................................
62-103 kPa (9-15 psi) Oil Filter Type ...................................................................................................
..................................................................................................... Full Flow Oil Pressure Switch
Actuating Pressure (Min)
........................................................................................................................................ 14-28 kPa
(2-4 psi)
CAUTION: *If pressure is ZERO at curb idle, DO NOT run engine at 3,000 rpm.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Engine Lubrication > Oil Pump, Engine > Engine Oil
Pressure > Component Information > Specifications > Page 1849
Engine Oil Pressure: Testing and Inspection
Check oil pressure using gauge at oil pressure switch location. Oil pressure should be 34.47 kPa (5
psi) at idle or 205 to 551 kPa (30 to 80 psi) at 3000 RPM.
Checking Oil Pump Pressure
1. Remove pressure sending unit and install oil pressure gauge.
CAUTION: If oil pressure is 0 at idle, do not run engine at 3000 RPM.
2. Warm engine at high idle until thermostat opens.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Technical Service Bulletins > Aluminum Engine - Gasket Surface Preparation
Intake Manifold: Technical Service Bulletins Aluminum Engine - Gasket Surface Preparation
NO: 09-09-97
GROUP: Engine
DATE: Dec. 19, 1997
SUBJECT: Gasket Surface Preparation On Aluminum Engine Components
MODELS: 1995
(AA) Acclaim/Spirit
1995 (AJ) Lebaron Convertible
1995 (AS) Caravan/Voyager/Town & Country
1995 - 1998 (FJ) Avenger/Sebring/Talon
1995 - 1998 (JA) Breeze/Cirrus/Stratus
1996 - 1998 (JX) Sebring Convertible
1995 - 1998 (LH) Concorde/Intrepid/Vision/LHS/New Yorker
1996 - 1998 (NS) Caravan/Voyager/Town & Country
1995 - 1998 (PL) Neon
1997 (PR) Prowler
DISCUSSION: Many aluminum engine components are being received by the material return
center with gouges, scratches, and out of flat conditions on the sealing surface. Caution must be
exercised when cleaning aluminum engine components. The use of solvents and plastic or wooden
scrapers are the only approved methods for removing gasket material.
NOTE:
DO NOT USE METAL SCRAPERS GRINDING DISCS OR ABRASIVES TO CLEAN ALUMINUM
ENGINE COMPONENTS. DAMAGE TO THE SEALING SURFACE WILL OCCUR.
Engine components received by the material return center will be evaluated for appropriate gasket
removal procedures. Components returned with obvious damage caused by improper gasket
removal procedures may be denied for warranty reimbursement.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Torque Sequence
Intake Manifold Bolts Location And Tightening Sequence
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Torque Sequence > Page 1856
Intake Manifold: Specifications Torque Specifications
DESCRIPTION ....................................................................................................................................
............................................................... TORQUE
Throttle Body Mounting Bolts
............................................................................................................................................................
23 Nm (200 inch lbs.) Lower Intake Mounting Bolts
.............................................................................................................................................................
23 Nm (200 inch lbs.) Upper Plenum Bolts .........................................................................................
................................................................................... 28 Nm (250 inch lbs.) Plenum Support
Bracket ................................................................................................................................................
........................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1857
Intake Manifold: Description and Operation
INTAKE/EXHAUST MANIFOLD
The intake manifold is a tuned two-piece semi-permanent mold aluminum casting with individual
primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque in
the 3600 rpm range and contributes to the engine's broad, flat torque curve, which was desired for
excellent engine tractability, response and usable power output. The intake manifold is also cored
with upper level EGR passages for balanced cylinder to cylinder EGR distribution. The exhaust
manifolds are log type with a crossover and are attached directly to the cylinder heads. They are
made from nodular cast iron.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information >
Specifications > Page 1858
Intake Manifold: Testing and Inspection
An intake manifold air leak is characterized by lower than normal manifold vacuum. Also, one or
more cylinders may not be functioning.
WARNING: USE EXTREME CAUTION WHEN THE ENGINE IS OPERATING. DO NOT STAND IN
A DIRECT LINE WITH THE FAN. DO NOT PUT YOUR HANDS NEAR THE PULLEYS, BELTS OR
THE FAN. DO NOT WEAR LOOSE CLOTHING.
1. Start the engine. 2. Spray a small stream of water (Spray Bottle) at the suspected leak area. 3. If
a change in RPM'S, the area of the suspected leak has been found. 4. Repair as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection
Intake Manifold: Service and Repair Cleaning and Inspection
INSPECTION
Check for: ^
Damage and cracks of each section.
^ Clogged water passages in end cross-overs (if equipped).
^ Check for cylinder head mounting surface distortion using a straightedge and thickness gauge.
CLEANING
Remove the gasket material from the manifold surfaces. Be careful not to gouge or scratch the
sealing surface.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1861
Intake Manifold: Service and Repair Intake Manifold Replacement
Removal
1. Remove windshield wiper module.
2. Perform fuel system pressure release procedure (before attempting any repairs).
3. Drain cooling system.
4. Remove air inlet resonator to throttle body hose assembly.
5. Remove throttle cable. Remove wiring harness from throttle cable bracket.
6. Remove Automatic Idle Speed (AIS) motor and Throttle Position Sensor (TPS) wiring connectors
from throttle body.
7. Remove EGR transducer connector.
8. Remove vacuum hose harness from throttle body.
9. Remove PCV and brake booster hoses from air intake plenum.
10. Disconnect MAP Sensor electrical connection.
11. Remove EGR tube flange from intake plenum.
12. Remove vacuum harness connectors from intake plenum.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1862
13. Remove cylinder head to intake plenum strut.
14. Remove the engine mounted ground strap.
15. Remove the fuel hose quick connect fitting from the fuel line by using an open end wrench
pushing in on the plastic ring located on the end of the fittings. Gently pull the fitting from the fuel
line.
CAUTION: Wrap a shop towel around hoses to catch any gasoline spillage during removal.
16. Remove Direct Ignition System (DIS) coils and generator bracket to intake manifold bolt.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1863
17. Remove bolts from generator to intake manifold bracket. Loosen top generator mounting bolt,
and move bracket up so intake manifold can clear mounting studs.
18. Remove intake manifold bolts and remove the manifold.
19. Cover intake manifold with suitable cover when servicing.
20. Remove vacuum harness connector from Fuel Pressure Regulator.
21. Remove fuel tube retainer bracket screw and fuel rail attaching bolts. Spread the retainer
bracket to allow fuel tube removal clearance.
22. Disconnect cam sensor and coolant temperature sensor.
23. Remove fuel injector wiring clip from intake manifold water tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1864
24. Remove fuel rail. Be careful not to damage the rubber injector O-rings upon removal from their
ports.
Intake Manifold Bolts Location And Tightening Sequence
25. Remove upper radiator hose, bypass hose and rear intake manifold hose.
26. Remove intake manifold bolts. Remove intake manifold.
27. Inspect and clean manifold.
WARNING: INTAKE MANIFOLD GASKET IS MADE OF VERY THIN METAL AND MAY CAUSE
PERSONAL INJURY, HANDLE WITH CARE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1865
28. Remove intake manifold seal retainers screws. Remove intake manifold gasket.
Installation
1. Clean all surfaces of cylinder block and cylinder heads.
2. Place a drop (approximately 1/4 inch diameter) of Mopar (R) Silicone Rubber Adhesive Sealant
or equivalent, onto each of the four manifold to cylinder head gasket corners.
3. Carefully install the new intake manifold gasket. Torque end seal retainer screws to 12 Nm (105
inch lbs.).
Intake Manifold Bolts Location And Tightening Sequence
4. Install intake manifold and bolts and torque to 1 Nm (10 inch lbs.). Then torque bolts to 22 Nm
(200 inch lbs.) in sequence shown. Then torque again to 22 Nm (200 inch lbs.). After intake
manifold is in place, inspect to make sure seals are in place.
5. Make sure the injector holes are clean and all plugs have been removed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1866
6. Lube injector O-ring with a drop of clean engine oil to ease installation.
7. Put the tip of each injector into their ports. Push the assembly into place until the injectors are
seated in the ports.
8. Install the fuel rail attaching bolts and torque to 22 Nm (200 inch lbs.).
9. Install fuel tube retaining bracket screw and torque to 4 Nm (35 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1867
10. Connect cam sensor and coolant temperature sensor.
11. Connect fuel pressure regulator vacuum line.
12. Remove covering on lower intake manifold and clean surface.
13. Place the new intake manifold gasket on lower manifold. Put upper manifold into place and
install bolts and nuts finger tight.
NOTE: At no time should the studs be replaced with a bolt and washer.
14. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold
strut bolts. (Do not torque.)
15. Torque intake manifold bolts to 28 Nm (250 inch lbs.) following torque sequence.
16. Torque generator bracket to intake manifold bolt to 54 Nm (40 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1868
17. Torque the cylinder head to intake manifold strut bolts to 54 Nm (40 ft. lbs.).
18. Connect ground strap and MAP sensor electrical connectors.
19. Connect vacuum harness to intake plenum.
20. Using a new gasket, connect the EGR tube flange to the intake manifold and torque to 22 Nm
(200 inch lbs.).
21. Clip wiring harness into the hole in the throttle cable bracket.
22. Connect the wiring connectors to the Throttle Position Sensor (TPS) and Automatic Idle Speed
(AIS) motor.
23. Connect vacuum harness to throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Intake Manifold > Component Information > Service
and Repair > Cleaning and Inspection > Page 1869
24. Install the Direct Ignition System (DIS) coils. Torque fasteners to 12 Nm (105 inch lbs.).
25. Lubricate the end of the chassis fuel tube with 30 WT oil. Connect fuel supply hose to chassis
fuel tube assembly. Pull back on the quick connect fitting to ensure complete insertion.
26. Install throttle cable.
27. Connect fuel injector wiring harness.
28. Install air cleaner and hose assembly.
29. Connect negative battery cable.
30. With the Diagnostic Readout Box (DRB) Scan Tool use Auto Shutdown (ASD) Fuel System
Test to pressurize system to check for leaks.
CAUTION: When using the ASD Fuel System Test, The ASD Relay will remain energized for 7
minutes or until the ignition switch is turned to the OFF position, or Stop All Test is selected.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Crankshaft Main
Bearing Seal > Component Information > Service and Repair
Crankshaft Main Bearing Seal: Service and Repair
REMOVAL
Rear Crankshaft Oil Seal-Removal
1. Insert a 3/16 flat bladed pry tool between the dust lip and the metal case of the crankshaft seal.
Angle the pry tool through the dust lip against
metal case of the seal. Pry out seal.
CAUTION: Do not permit the pry tool blade to contact crankshaft seal surface. Contact of the pry
tool
INSTALLATION
CAUTION: If burr or scratch is present on the crankshaft edge (chamfer), cleanup with 400 grit
sand paper to prevent seal damage during installation of new seal.
Rear Crankshaft Oil Seal-Installation
1. Place Special Tool 6926-1 magnetic pilot tool on crankshaft. 2. Lightly coat seal O.D. with Mopar
(R) Stud N' Bearing Mount Adhesive or equivalent. 3. Place seal over Special Tool 6926-1 Pilot.
Using Special Tool 6926-2 Installer with C-4171 Handle, drive seal into the retainer housing.
Rear Crankshaft Seal Retainer
When retainer removal is required, remove retainer and clean engine block and retainer of old
gasket. Make sure surfaces are clean and free of oil. Install new gasket and tighten screws to 12
Nm (105 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair
Front Crankshaft Seal: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Raise vehicle on hoist. Remove right wheel and inner
splash shield. 3. Remove accessory drive belt.
Crankshaft Damper-Removal
4. Remove crankshaft damper.
Front Crankshaft Oil Seal-Removal
5. Remove oil seal using Special Tool 6341. Be careful not to damage the crankshaft seal surface
of cover.
INSTALLATION
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Front Crankshaft Seal
> Component Information > Service and Repair > Page 1877
Crankshaft Oil Seal-installation
1. Install new seal using Special Tool C-4992. 2. Place seal into opening with seal spring towards
the inside of engine. Install seal until flush with cover.
Crankshaft Damper-Installation
3. Install crankshaft pulley using plate L-4524. Thrust Bearing/washer and C-4685-C1, 5.9 inch
screw. 4. Install accessory drive belt. 5. Install inner splash shield and wheel. 6. Lower vehicle and
connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Intake Manifold Gasket
> Component Information > Specifications
Intake Manifold Gasket: Specifications
Gasket Retaining Screws ....................................................................................................................
................................................. 12 Nm (105 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Seals and Gaskets, Engine > Valve Guide Seal >
Component Information > Service and Repair
Valve Guide Seal: Service and Repair
1. Perform fuel system pressure release procedure before attempting any repairs. 2. Disconnect
negative cable from battery. 3. Remove air cleaner cover and hose assembly. 4. Remove upper
intake manifold. 5. Remove cylinder head covers and spark plugs. 6. Remove electrical connector
from ignition coils. 7. Using suitable socket and flex handle at crankshaft pulley retaining screw,
turn engine so the number 1 piston is at Top Dead Center on the
compression stroke.
8. Remove rocker arms with rocker shaft and install a dummy shaft. The rocker arms should not be
disturbed and left on shaft. 9. With air hose attached to spark plug adapter installed in number 1
spark plug hole, apply 90 to 100 psi air pressure (620.5 to 689 kPa). This is to
hold valves in place while servicing components.
10. Using Tool C-4682 or equivalent, compress valve spring and remove retainer valve locks and
valve spring. 11. The intake valve stem seals should be pushed firmly and squarely over the valve
guide using the valve stem as guide. Do Not Force seal against
top of guide. When installing the valve retainer locks, compress the spring only enough to install
the locks.
CAUTION: Do not pinch seal between retainer and top of valve guide.
12. Follow the same procedure on the remaining 5 cylinders using the firing sequence 1-2-3-4-5-6.
Make sure piston in cylinder is at TDC on the valve
spring that is being covered.
13. Remove spark plug adapter tool. 14. Remove dummy shaft and install rocker shaft assembly
and tighten screws to 28 Nm (250 inch lbs.). 15. Install cylinder head covers tighten screws to 14
Nm (120 inch lbs.) and electrical connector to ignition coils. 16. Install Intake Manifold. 17. Connect
negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Sensors and Switches - Engine > Oil Pressure
Sender > Component Information > Locations
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Camshaft Gear/Sprocket >
Component Information > Specifications
Camshaft Gear/Sprocket: Specifications
Camshaft Sprocket Bolt .......................................................................................................................
.................................................... 54 Nm (40 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Specifications
Timing Chain: Specifications
Number of Links ..................................................................................................................................
.............................................................................. 64
Pitch .....................................................................................................................................................
................................................................. 0.375 inch
Width ...................................................................................................................................................
.................................................................. 0.750 inch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch
Timing Chain: Service and Repair Measuring Timing Chain Stretch
1. Place a scale next to timing chain so that any movement of chain may be measured. 2. Place a
torque wrench and socket on camshaft sprocket attaching bolt and apply torque in direction of
crankshaft rotation to take up slack; 41 Nm
(30 ft. lbs.) with cylinder head installed or 20 Nm (15 ft. lbs.) with cylinder heads removed. With a
torque applied to the camshaft sprocket bolt, crankshaft should not be permitted to move. It may be
necessary to block crankshaft to prevent rotation.
Measuring Timing Chain Wear And Stretch
3. Holding a scale even, with dimension reading as shown, along edge of chain links. Apply torque
in the reverse direction to 41 Nm (30 ft. lbs.) with
cylinder heads installed, or 20 Nm (15 ft. lbs.) with cylinder heads removed. Check amount of chain
movement.
4. Install a new timing chain, if its movement exceeds 3.175 mm (1/8 inch). 5. If chain is not
satisfactory, refer to Timing Chain Removal and Installation in this section.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Chain > Component
Information > Service and Repair > Measuring Timing Chain Stretch > Page 1897
Timing Chain: Service and Repair Timing Chain Replacement
REMOVAL
1. Disconnect negative cable from battery. 2. Remove timing chain cover. 3. Remove camshaft
sprocket attaching bolt, and timing chain with camshaft sprocket. 4. Using a suitable puller remove
the crankshaft sprocket. Be careful not to damage the crankshaft surface.
INSTALLATION
1. Position a new crankshaft sprocket on the shaft, install sprocket with suitable tool and mallet. Be
sure sprocket is seated into position. 2. Rotate crankshaft so the timing arrow is to the 12 o'clock
position. 3. Place timing chain around camshaft sprocket and place the timing mark to the 6 o'clock
position. 4. Align the dark colored links with the dot on the camshaft sprocket, place timing chain
around crankshaft sprocket with the dark colored link lined
up with the dot on the sprocket and install camshaft sprocket into position.
Timing Marks Alignment
5. Use a straight edge to check alignment of timing marks. 6. Install camshaft bolt and washer.
Tighten to 54 Nm (40 ft. lbs.). 7. Rotate crankshaft 2 revolutions. Timing marks should line up. If
timing marks do not line up remove cam sprocket and realign. 8. Check camshaft end play. With
new thrust plate the specification is 0.0127 to 0.304 mm (0.005 to 0.012 inch). Old thrust plate
specification is
0.31 mm (0.012 inch) maximum. If not within these limits install new thrust plate.
9. Install timing chain cover and connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications
Timing Cover: Specifications
Bolt-M8 X 1.25 .....................................................................................................................................
................................................... 27 Nm (20 ft. lbs.) Bolt-M10 X 1.5 ...................................................
..................................................................................................................................... 54 Nm (40 ft.
lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 1901
Timing Cover: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Drain cooling system. 3. Support engine and remove
right engine mount. 4. Raise vehicle on hoist. Drain engine oil. 5. Remove oil pan and oil pump
pick-up. It may necessary to remove transaxle inspection cover. 6. Remove right wheel and inner
splash shield. 7. Remove drive belt. 8. Remove A/C compressor and set aside. 9. Remove A/C
compressor mounting bracket.
Crankshaft Damper-Removal
10. Remove crankshaft damper. 11. Remove idler pulley from engine bracket.
Engine Bracket
12. Remove engine bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 1902
Timing Chain Case Cover
13. Remove cam sensor from chain case cover. 14. Remove chain case cover.
INSTALLATION
1. Be sure mating surfaces of chain case cover and cylinder block are clean and free from burrs.
Crankshaft oil seal must be removed to insure
correct oil pump engagement.
NOTE: Do not use sealer on cover gasket.
Timing Chain Case Cover Gaskets And O-Rings
2. Use a new cover gasket, and O-rings. Adhere new gasket to chain case cover, making sure that
the lower edge of the gasket is flush to 0.5 mm
(0.020 inch) passed the lower edge of the cover. Refer to Oil Pan sealing.
3. Rotate crankshaft so that the oil pump drive flats are vertical. 4. Position oil pump inner rotor so
the mating flats are in the same position as the crankshaft drive flats. 5. Install cover onto
crankshaft. Make sure the oil pump is engaged on the crankshaft correctly or severe damage may
result. 6. Install chain case cover screws and torque to 27 Nm (20 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Timing Components > Timing Cover > Component
Information > Specifications > Page 1903
Crankshaft Oil Seal-Installation
7. Install crankshaft oil seal.
Crankshaft Damper-Installation
8. Install crankshaft pulley. 9. Install engine bracket and torque fasteners to 54 Nm (40 ft. lbs.).
10. Install idler pulley on engine bracket. 11. Install cam sensor. Refer to Ignition System for
installation procedure. 12. Install A/C compressor mounting bracket. 13. Install A/C compressor.
14. Install drive belt Refer to Cooling System for installation procedure. 15. Install inner splash
shield and wheel. 16. Install oil pump pick-up and oil pan and transaxle inspection cover if
removed. 17. Install engine mount. 18. Fill crankcase with oil to proper level. 19. Fill cooling
system. 20. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Pressure > Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 1910
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air/Fuel
Mixture > System Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1917
Idle Speed: Testing and Inspection
THROTTLE BODY MINIMUM AIR FLOW CHECK
Fig 97 Air Metering Fitting 6457
Fig 100 PCV Valve
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the
intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457
(0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from
the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link
connector.
10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The
following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
airflow is set correctly.
2.4L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 500-875 RPM
Above 1000 Miles 550-875 RPM
3.0L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 560-910 RPM
Above 1000 Miles 610-910 RPM
3.3L/3.8L Idle Specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Idle
Speed > System Information > Specifications > Page 1918
Odometer Reading Idle RPM
Below 1000 Miles 525-875 RPM
Above 1000 Miles 575-875 RPM
14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let
Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash
thoroughly after using cleaner.
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle
purge line. 18. Remove DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Fig 125 Air Inlet Resonator
REMOVAL
1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner
housing halves together.
Fig 126 Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing (Fig. 126).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Air
Cleaner Housing > Air Filter Element > Component Information > Service and Repair > Page 1923
Fig 127 Air Cleaner Element
4. Remove element from air cleaner housing (Fig. 127).
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Fuel
Filter > Fuel Pressure Release > System Information > Service and Repair > CNG Engine > Page 1929
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Firing
Order > Component Information > Specifications
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Number One Cylinder > Component Information > Locations
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Timing > Timing Marks and Indicators > System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Specifications
Ignition Cable: Specifications
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Specifications > Page 1943
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
PURPOSE
Transfer electrical current from the coil to the individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
CONSTRUCTION
The spark plug cables and spark plug boots are made from high temperature silicone materials.
Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust
manifold. The heat shields slide over the spark plug boots.
- The notches on the heat shields ensure the spark plug boot and shield twist together during spark
plug boot removal.
- They also identify proper heat shield installation on the boot for service.
- All spark plug cable leads are properly identified with cylinder numbers.
Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure.
- Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent
or missing.
- Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems.
- The bottom of the spark plug heat shield must make contact with the spark plug hex.
Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone
grease for greater sealing and to minimize boot bonding to the spark plug insulator.
The convoluted tubing on the rear plug cables are made of a high temperature plastic material.
Service Life Under normal driving conditions, the spark plug cables have a recommended service
life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for
severe driving conditions.
CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable
must not touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 1946
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter.
- Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
INSPECTION
Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good
condition.
Covers should fit tightly on the coil pack and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
Secondary Ignition Cable Resistance Test
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service and Repair > Replacing Cables
Ignition Cable: Service and Repair Replacing Cables
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
- Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
- Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can
damage the ignition cable conductor.
SPARK PLUG CABLES #3 AND #5
Removal
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug.
- Twist the boot slightly to break its seal with the plug and pull straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the
retaining bracket.
- Make sure that they are also detached from the rear retaining clip mounted on the rear of the
intake manifold.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
SPARK PLUG CABLE #1
Removal
1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the
upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug
boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal
with the plug and pull
straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
5. Wipe spark plug insulator clean with a dry cloth before installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service and Repair > Replacing Cables > Page 1949
6. Remove the cable from the retaining bracket.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt, refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Ignition
Cable > Component Information > Service and Repair > Replacing Cables > Page 1950
Ignition Cable: Service and Repair Cleaning Cables
Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables
dry. Check for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1954
Spark Plug: Service Precautions
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1955
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Specifications > Page 1956
Spark Plug: Description and Operation
Fig 3 Platinum Plug Pads
NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal driving conditions. The recommended
service life under severe conditions is 75,000 miles.
- A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3).
- Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator
damage during plug removal and installation.
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator.
CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs.
This would damage the platinum pads which would shorten spark plug life.
Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's
original spark plugs that have been determined good. -
Do not apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-seize compound does not make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark
plugs without reading the procedures.
Due to the engine packaging environment for this engine, extreme care should be used when
installing the spark plugs to avoid cross threading problems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1959
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1960
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1961
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1962
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1963
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1964
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 1965
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: -
In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Page 1966
Spark Plug: Adjustments
Setting Spark Plug Gap - Typical
Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or
oil fouled.
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Page 1967
Spark Plug: Service and Repair
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- Use extreme care when removing and installing the spark plug cables.
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
SPARK PLUG #3 AND #5
REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head.
3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield
assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break
the seal with the
plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
SPARK PLUG #1
REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts
from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark
plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly
slightly to break its seal with the
plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Spark
Plug > Component Information > Testing and Inspection > Page 1968
insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before
installation.
5. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure the coil or spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt, refer to Cooling System.
OTHER PLUGS
REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering
combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while
pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR: Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle
operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this
will allow deposit shifting in the combustion chamber to take place gradually and avoid plug
destroying splash fouling shortly after the plug change.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications
Compression Check: Specifications
Compression Ratio ..............................................................................................................................
........................................................................... 8.9:1 Minimum Compression ...................................
........................................................................................................................................ 689.5 kPa
(100 psi) Maximum Variation Between Cylinders ................................................................................
......................................................................................... 25%
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks >
Compression Check > System Information > Specifications > Page 1972
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. Ensure the battery is completely charged and the engine starter motor is in good
operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis
purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System (DIS) disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to
specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and
secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and
different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and
Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt
drives. 18. Road test vehicle as a final test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Tune-up and Engine Performance Checks > Valve
Clearance > System Information > Specifications
Valve Clearance: Specifications
This engine is equipped with hydraulic valve lifters and are not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Water Pump Bolts
Water Pump: Specifications
Water Pump Pulley Bolts 250 in.lb
Water Pump Mounting Bolts 105 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information >
Specifications > Water Pump Bolts > Page 1980
Water Pump: Specifications Water Pump Pulley Bolts
Bolts .....................................................................................................................................................
.................................................. 28 Nm (250 in. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description
and Operation > Description and Operation
Water Pump: Description and Operation
The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring. for sealing. It is driven by the back surface of the Poly-V Drive Belt.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description
and Operation > Description and Operation > Page 1983
Water Pump: Description and Operation General Information
A quick test to tell whether the pump is working is to see if the heater warms properly. A defective
pump can not circulate heated coolant through the long heater hose. The water pump on all models
can be replaced without discharging the air conditioning system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description
and Operation > Page 1984
Water Pump: Testing and Inspection
Replace the water pump if it has any of the following defects. 1. Damage or cracks on the pump
body. 2. Coolant leaks; if the seal is leaking, this will be evident by traces of thick deposits of
greenish-brown dried glycol running down the pump body
and components below. A thin black stain below pump weep hole is considered normal operation.
3. Impeller rubs inside of chain case cover. 4. Excessively loose or rough turning bearing.
NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole
(black stain on water pump body). Do not replace the water pump if this condition exists. Replace
the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on
water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis
before replacing water pump.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Engine > Water Pump > Component Information > Description
and Operation > Page 1985
Water Pump: Service and Repair
REMOVAL
1. Drain Cooling System. 2. Remove Poly-V Drive Belt. 3. Remove right front lower fender shield.
4. Remove pump pulley bolts and remove pulley.
Water Pump
5. Remove pump mounting screws. Remove water pump. 6. Remove and discard O-ring seal. 7.
Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch
or gouge sealing surface.
INSTALLATION
Water Pump Body
1. Install new O-ring into groove. 2. Install pump to chain case cover. Torque screws to 12 Nm (105
inch lbs.) 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump.
Install screws and torque to 30 Nm (250 inch lbs.). 5. Install drive belt. 6. Install right front lower
fender shield. 7. Refill Cooling System. See Refilling Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications
Coolant: Capacity Specifications
COOLING SYSTEM CAPACITY
2.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 10.6 L (11.23 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.................................................................. N/A Rear Heater ...............................................................
............................................................................................................................................. N/A
3.0L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
............................................................................................................................................. N/A
Trailer Tow
Front Heater ........................................................................................................................................
.............................................. 12.3 L (13.0 qts) Rear Heater ...............................................................
........................................................................................................................ 15.0 L (15.9 qts)
3.3/3.8L ENGINE
Standard Duty
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
Trailer Tow
Front Heater ........................................................................................................................................
............................................ 12.5 L (13.23 qts) Rear Heater ...............................................................
.................................................................................................................... 15.26 L (16.13 qts)
NOTE: Capacities include heater and coolant recovery tank filled to Max level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Specifications > Capacity Specifications > Page 1991
Coolant: Fluid Type Specifications
The required ethylene-glycol (antifreeze) and water mixture depends upon the climate and vehicle
operating conditions. The recommended mixture of 50/50 ethylene-glycol and water will provide
protection against freezing to -37° C (-35° F). The antifreeze concentration must always be a
minimum of 44%, year round, in all climates. If percentage is lower than 44%, engine parts may be
eroded by cavitation, and cooling system components may be severely damaged by corrosion.
Maximum protection against freezing is provided with a 68% antifreeze concentration, which
prevents freezing down to -67.7° C (-90° F). A higher percentage will freeze at a warmer
temperature. Also, a higher percentage of antifreeze can cause the engine to overheat because the
specific heat of antifreeze is lower than that of water.
100 Percent Ethylene-Glycol Should Not Be Used
Use of 100 Percent Ethylene-Glycol will cause formation of additive deposits in the system, as the
corrosive inhibitive additives in ethylene-glycol require the presence of water to dissolve. The
deposits act as insulation, causing temperatures to rise as high as 149° C (300° F). this
temperature is hot enough to melt plastic and soften solder. The increased temperature can result
in engine detonation. In addition, 100 % ethylene-glycol freezes at 22° C (-8° F).
Propylene-Glycol Formulations Should Not Be Used
Propylene-glycol formulations do not meet the required specifications. It's overall effective
temperature range is smaller than that of ethylene-glycol. The freeze point of 50/50
propylene-glycol and water is -32° C (-26° F), 5 degrees higher than ethylene-glycol's freeze point.
The boiling point (protection against summer boil-over) of propylene-glycol is 125° C (257° F) at
96.5 kPa (14 PSI), compared to 128° C (263° F) for ethylene-glycol. Use of propylene-glycol can
result in boil-over and freeze up. Propylene-Glycol also has a poorer heat transfer characteristics
than ethylene-glycol. This can increase cylinder head temperatures under certain conditions.
Propylene-Glycol/Ethylene-Glycol Mixtures Should Not Be Used
Propylene-glycol/ethylene-glycol mixtures can cause the destabilization of various corrosion
inhibitors, causing damage to the coling system components. Also, once ethylene-glycol and
propylene-glycol based coolants are mixed in the vehicle, conventional methods of determining the
freeze point will not be accurate. Both the refractive index and specific gravity differ between the
ethylene-glycol and propylene-glycol.
CAUTION: Richer antifreeze mixtures cannot be measured with normal field equipment and can
cause problems associated with 100 percent ethylene-glycol.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > General Information
Coolant: Description and Operation General Information
The cooling system is designed around the coolant. The coolant must accept heat from engine
metal, in the cylinder head area near the exhaust valves. Coolant then carries this heat to the
radiator, where the tube/fin assemblies of these components can give it up to the air. The use of
aluminum cylinder heads, intake manifolds, and water pumps requires special corrosion protection.
Mopar (R) Antifreeze or the equivalent is recommended for best engine cooling without corrosion,
when mixed only to a freeze point of -37°C (-35°F) to -59°C (-50°F). If it loses color or becomes
contaminated, drain, flush, and replace with fresh properly mixed solution.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > General Information > Page 1994
Coolant: Description and Operation
Performance is measurable. For heat transfer pure water excels (Formula = 1 btu per minute for
each degree of temperature rise for each pound of water). This formula is altered when necessary
additives to control boiling, freezing, and corrosion are added as follows: Pure Water (1 btu) boils at 100°C (212°F) and freezes at 0°C (32°F)
- 100 percent Glycol (.7 btu) can cause a hot engine and detonation and will lower the freeze point
to-22°C (-8°F).
- 50/50 Glycol and Water (.82 btu) is the recommended combination that provides a freeze point of
-37°C (-35°F). The radiator, water pump, engine water jacket, radiator pressure cap, thermostat,
temperature gauge, sending unit and heater are all designed for 50/50 glycol.
CAUTION: Do not use well water, or suspect water supply in cooling system. A 50/50 ethylene
glycol and distilled water mix is recommended.
Where required, a 56 percent glycol and 44 percent water mixture will provide a freeze point of
-59°C (-50°F)
CAUTION: Richer mixtures cannot be measured with field equipment. This can lead
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Coolant > Component Information >
Description and Operation > Page 1995
Coolant: Service and Repair
Refer to Cooling System, Service and Repair for applicable service procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection
Radiator Cooling Fan Motor: Testing and Inspection
Fan control is accomplished two ways. A pressure transducer on the compressor discharge line
sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to
this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant
temperature sensor which sends the message to the PCM. The fan will not run during cranking
until the engine starts no matter what the coolant temperature is.
CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support.
The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is
properly attached to prevent the following:
- Intermittent engine overheating.
- Relay "thermal" shutdown, or relay damage.
For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code
Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor > Component Information > Testing and Inspection > Page 2000
Radiator Cooling Fan Motor: Service and Repair
REMOVAL
Fan Module
There are no repairs to be made to the fan or shroud assembly. If the fan is warped, cracked, or
otherwise damaged, it must be replaced as a assembly. 1. Raise the vehicle on hoist. 2. Remove
the radiator outlet hose from hose retaining clip and remove clip from shroud. 3. Remove lower
auxiliary transmission cooler lines from retaining clips on the fan module shroud, if equipped. 4.
Lower the vehicle. Remove the air intake resonator from the throttle body and air cleaner
assembly. 5. Disconnect the fans electrical connector located on the left side of the fan module. 6.
Remove the Coolant Recovery System (CRS) attaching screw from the upper crossmember. 7.
Remove upper grill to crossmember valence panel. 8. Disconnect the upper radiator mounts from
the crossmember. Remove the upper crossmember. 9. Remove the air cleaner assembly.
10. Remove fan module retaining fasteners. 11. Remove upper auxiliary transmission cooler lines
from retaining clips on the fan module shroud, if equipped. 12. Disconnect and plug the
transmission line from the radiator fitting on the lower left side. 13. Raise vehicle on the hoist and
remove the filter/drier, fan module and radiator mounting bolts located on the lower right of the
module. 14. Lower the vehicle on hoist and remove the upper fan module to radiator retaining clips.
15. Remove the fan module from the vehicle.
INSTALLATION
1. Install fan module assembly into attaching clips on the radiator. 2. Install the upper fan module to
radiator retaining clips. 3. Raise vehicle on the hoist and install the filter/drier, fan module and
radiator mounting fasteners located on the lower right of the module. 4. Lower the vehicle. Connect
the transmission line to the radiator fitting on the lower left side. 5. Install the upper auxiliary
transmission cooler lines to the retaining clips on the fan module shroud, if equipped. 6. Install fan
module retaining fasteners. Tighten to 12 Nm (105 inch lbs.). 7. Install the air cleaner assembly. 8.
Install the crossmember. Connect the upper radiator mounts to the crossmember. Tighten
fasteners to 12 Nm (105 inch lbs.). 9. Install the Coolant Recovery System (CRS) attaching screw
to the upper crossmember. Tighten to 2 Nm (18 inch lbs.).
10. Install upper grill to crossmember valence panel. 11. Connect the fans to the connector located
on the left side of the fan module. 12. Install the air intake resonator to the throttle body and air
cleaner assembly. 13. Raise the vehicle. Install the lower auxiliary transmission cooler lines to the
retaining clips on the fan module shroud, if equipped. 14. Install outlet hose retainer clip to the
shroud. Install the radiator outlet hose to the retaining clip. 15. Lower the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2009
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2010
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2011
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign Radiator Fan Relay and PCM > Page 2012
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 >
PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: Customer Interest PCM - Improper Cooling Fan Relay
Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 >
PCM - Improper Cooling Fan Relay Actuation > Page 2018
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2024
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2025
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2026
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2027
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan
Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Radiator
Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2032
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan
Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2038
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2044
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2045
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2046
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for Radiator Cooling
Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2047
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2048
Radiator Cooling Fan Motor Relay: Locations
Cooling Fan Relay Location
Radiator Fan Relay Mounted On Left Front Frame Rail
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2049
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2050
Radiator Cooling Fan Motor Relay: Description and Operation
Fig 41 Fan Control Module
SOLID STATE FAN RELAY -- PCM OUTPUT
The radiator fan runs at a variable speed depending on coolant temperature and A/C system
pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR).
A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR.
Depending upon the amount of pulse ON time, the SSFR puts out a proportional voltage to the fan
motor at the lower speed. For instance, if the ON time is 30 percent, then the voltage to the fan
motor will be 3.6 volts.
when engine coolant temperature reaches approximately 102°C (215°F) the PCM grounds the
SSFR. If engine coolant reaches 107°C (225°F) the PCM grounds the high speed ground relay and
high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay
and high speed ground relay when coolant temperature drops to approximately 101°C (214°F).
When coolant temperature drops to 101°C (214°F) the fan operates at low speed. The PCM
de-energizes the low speed relay when coolant temperature drops to approximately 93°C (199°F).
Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air
conditioning switch closes at 285 psi ±10 psi. When air conditioning pressure drops approximately
40 psi, the pressure switch opens and the fan operates at low speed.
The SSFR is located on the left front inner frame -- just behind the radiator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cooling Fan > Radiator Cooling
Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2051
Radiator Cooling Fan Motor Relay: Testing and Inspection
Fan control is accomplished two ways. A pressure transducer on the compressor discharge line
sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to
this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant
temperature sensor which sends the message to the PCM. The fan will not run during cranking
until the engine starts no matter what the coolant temperature is.
CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support.
The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is
properly attached to prevent the following:
- Intermittent engine overheating.
- Relay "thermal" shutdown, or relay damage.
For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code
Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
2056
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
2057
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
2058
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
2059
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component Information > Specifications > Page
2060
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Engine - Coolant Temperature
Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Gauge Sending Unit
........................................................................................................................................................... 7
Nm (60 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core
Heater Core: Service and Repair Front Heater Core
REMOVAL
1. Drain coolant system. See: Service and Repair 2. Remove left side lower column cover. Refer
to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
3. Remove steering column assembly. See: Steering and Suspension/Steering/Steering
Column/Service and Repair
ABS Module
4. Remove ABS module, bracket and wiring. See: Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Electronic Brake
Control Module/Service and Repair
Interconnect And Bracket
5. Remove I/P to body harness interconnect and bracket.
Lower Silencer Boot
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 2068
6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood.
Heater Core Plate And Tubes
8. Remove heater core cover. Insert a small amount of towels under the heater core tubes.
Remove heater core plate and tubes.
Depress Clips
9. Depress heater core retaining clips.
Accelerator Pedal
10. Pull up on accelerator pedal and slide heater core past.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 2069
Brake Pedal
11. Depress brake pedal and remove heater core from HVAC housing.
INSTALLATION
- For installation, reverse the above procedures. Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 N.m (27 ±
9 in. lbs.) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Core > Component Information >
Service and Repair > Front Heater Core > Page 2070
Heater Core: Service and Repair Rear Heater Core
REMOVAL
1. Remove the lower right quarter trim panel.
Heater Core Lines
2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4.
Carefully pull the heater core and tubes up and straight out of the unit.
INSTALLATION
Filling Heater Core
- For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall
performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be used: Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor on HIGH
- Discharge air temperature, measured at the dual register located on the C-pillar base, is between
57 degree Celsius to 62 degree Celsius (135 degree and 145 degree Fahrenheit).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Locations
Heater Hose: Locations
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Locations > Page 2074
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hoses
Heater Hose: Service and Repair Heater Hoses
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Drain engine cooling system.
Upper Heater Hose
Lower Heater Hose
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core in let or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hoses > Page 2077
Heater Hose: Service and Repair Underbody Plumbing
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Heater Hose > Component Information >
Service and Repair > Heater Hoses > Page 2078
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
For more information, refer to Heater core/ Service and Repair. See: Heater Core/Service and
Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Description and Operation
Temperature Gauge: Description and Operation
At idle with Air Conditioning off the temperature gauge will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to about 1/2 gauge travel. This is normal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Temperature Gauge: Initial Inspection and Diagnostic Overview
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See:
Instrument Panel, Gauges and Warning Indicators/Testing and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview >
Page 2085
Temperature Gauge: Component Tests and General Diagnostics
Temperature Diagnosis (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview >
Page 2086
Temperature Diagnosis (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Lamps and Indicators - Cooling System >
Temperature Gauge > Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview >
Page 2087
Temperature Diagnosis (Part 3 Of 3)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator > Radiator Drain Plug >
Component Information > Service and Repair
Radiator Drain Plug: Service and Repair
REMOVAL
CAUTION: Use of pliers on draincock is not recommended. Damage may occur to part. Draincock
should not be removed unless leakage observed.
Draincock Disassembled
1. Turn the draincock stem counterclockwise to unscrew the stem. When the stem is unscrewed to
the end of the threads turn back 1/8 turn and, pull
the stem from the radiator tank.
INSTALLATION
1. Push the draincock assembly body into the tank opening until it snaps into place. 2. Tighten the
draincock stem by turning clockwise until it stops.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Description and Operation
Radiator Cap: Description and Operation
The radiator is equipped with a pressure cap that releases excessive cooling system pressure;
maintaining a range of 97-124 kPa (14-18 psi). The cooling system will operate at higher than
atmospheric pressure. The higher pressure raises the coolant boiling point thus, allowing increased
radiator cooling capacity.
There is also a vent valve in the center of the cap. This valve also opens when coolant is cooling
and contracting allowing coolant to return to radiator from coolant reserve system tank by vacuum
through connecting hose. If valve is stuck shut, or the coolant recovery hose is pinched, the
radiator hoses will be collapsed on cool down. Clean the vent valve and inspect coolant recovery
hose routing, to ensure proper sealing when boiling point is reached. The gasket in the cap seals
the filler neck, so that vacuum can be maintained, allowing coolant to be drawn back into the
radiator from the reserve tank. If the gasket is dirty or damaged, a vacuum may not be achieved,
resulting is loss of coolant and eventual overheating due to low coolant level in radiator and engine.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview
Radiator Cap: Initial Inspection and Diagnostic Overview
Hold the cap in hand, right side up. The vent valve at the bottom of the cap should open. If the
rubber gasket has swollen and prevents the valve from opening, replace the cap. Hold the cleaned
cap in hand upside down. If any light shows between vent valve and rubber gasket, replace cap.
Do not use a replacement cap that has a spring to hold the vent shut. Replacement cap must be of
the type designed for coolant reserve system with a completely sealed diaphragm spring, and
rubber gasket to seal to filler neck top surface. This design assures coolant return to radiator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Cap > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2097
Radiator Cap: Component Tests and General Diagnostics
Radiator Cap - Pressure Testing
Dip the pressure cap in water, clean any deposits off the vent valve or its seat and apply cap to end
of Radiator Pressure Tool. Working the plunger, bring the pressure to 104 kPa (15 psi) on the
gauge. If the pressure cap fails to hold pressure of at least 97 kPa (14 psi) replace cap. See
CAUTION below.
If the pressure cap tests properly while positioned on Radiator Pressure Tool, but will not hold
pressure or vacuum when positioned on the radiator. Inspect the radiator filler neck and cap top
gasket for irregularities that may prevent the cap from sealing properly.
CAUTION: Radiator Pressure Tool is very sensitive to small air leaks that will not cause cooling
system problems. A pressure cap that does not have a history of coolant loss should not be
replaced just because it leaks slowly when tested with this tool. Add water to the tool. Turn tool
upside down and recheck pressure cap to confirm that cap is bad.
Radiator Cap to Filler Neck Seal - Pressure Relief Check
The pressure cap upper gasket (seal) pressure relief can be checked by removing the overflow
hose at the radiator filler neck nipple. Attach the Radiator Pressure Tool to the filler neck nipple and
pump air into the radiator. Pressure cap upper gasket should relieve at 69-124 kPa (10-18 psi) and
hold pressure at 55 kPa (8 psi) minimum.
WARNING: THE WARNING WORDS "DO NOT OPEN HOT" ON THE RADIATOR PRESSURE
CAP IS A SAFETY PRECAUTION. WHEN HOT, PRESSURE BUILDS UP IN COOLING SYSTEM.
TO PREVENT SCALDING OR INJURY, THE RADIATOR CAP SHOULD NOT BE REMOVED
WHILE THE SYSTEM IS HOT OR UNDER PRESSURE.
There is no need to remove the radiator cap at any time except for the following purposes: 1.
Check and adjust coolant freeze point. By adding or subtracting coolant through CRS bottle. 2.
Refill system with new coolant. 3. Conducting service procedures. 4. Checking for vacuum leaks.
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE REMOVING
CAP. THEN PLACE A SHOP TOWEL OVER THE CAP AND WITHOUT PUSHING DOWN
ROTATE COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW FLUIDS TO ESCAPE
THROUGH THE OVERFLOW TUBE AND WHEN THE SYSTEM STOPS PUSHING COOLANT
AND STEAM INTO THE CRS TANK AND PRESSURE DROPS PUSH DOWN AND REMOVE THE
CAP COMPLETELY. SQUEEZING THE RADIATOR INLET HOSE WITH A SHOP TOWEL (TO
CHECK PRESSURE) BEFORE AND AFTER TURNING TO THE FIRST STOP IS
RECOMMENDED.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Radiator Hose > Component Information >
Description and Operation
Radiator Hose: Description and Operation
WARNING: IF VEHICLE HAS BEEN RUN RECENTLY, WAIT 15 MINUTES BEFORE WORKING
ON VEHICLE. RELIEVE PRESSURE BY PLACING A SHOP TOWEL OVER THE CAP AND
WITHOUT PUSHING DOWN ROTATE IT COUNTERCLOCKWISE TO THE FIRST STOP. ALLOW
FLUIDS AND STEAM TO ESCAPE THROUGH THE OVERFLOW TUBE. THIS WILL RELIEVE
SYSTEM PRESSURE
The hoses are removed by using constant tension clamp pliers to compress the hose clamp. A
hardened, cracked, swollen or restricted hose should be replaced. Do not damage radiator inlet
and outlet when loosening hoses. Radiator hoses should be routed without any kinks and indexed
as designed. The use of molded hoses is recommended. Spring type hose clamps are used in all
applications. If replacement is necessary replace with the original Mopar (R) equipment spring type
clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 >
Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 >
Campaign - Radiator Fan Relay and PCM > Page 2110
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 >
Campaign - Radiator Fan Relay and PCM > Page 2111
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 >
Campaign - Radiator Fan Relay and PCM > Page 2112
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Recalls: > 771 > May > 98 >
Campaign - Radiator Fan Relay and PCM > Page 2113
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97
> Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: Customer Interest PCM - Improper Cooling Fan Relay
Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Customer Interest: > 18-33-97
> Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2119
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2125
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2126
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2127
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2128
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan
Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Technical Service Bulletins
for Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2133
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
Radiator Cooling Fan Motor Relay: All Technical Service Bulletins PCM - Improper Cooling Fan
Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 2139
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2145
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2146
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2147
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > All Other Service Bulletins for
Radiator Cooling Fan Motor Relay: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 2148
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2149
Radiator Cooling Fan Motor Relay: Locations
Cooling Fan Relay Location
Radiator Fan Relay Mounted On Left Front Frame Rail
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2150
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2151
Radiator Cooling Fan Motor Relay: Description and Operation
Fig 41 Fan Control Module
SOLID STATE FAN RELAY -- PCM OUTPUT
The radiator fan runs at a variable speed depending on coolant temperature and A/C system
pressure. The radiator fan circuit contains a Solid State Fan Relay (SSFR).
A 5 volt signal is supplied to the SSFR. The PCM provides a pulsed ground for the SSFR.
Depending upon the amount of pulse ON time, the SSFR puts out a proportional voltage to the fan
motor at the lower speed. For instance, if the ON time is 30 percent, then the voltage to the fan
motor will be 3.6 volts.
when engine coolant temperature reaches approximately 102°C (215°F) the PCM grounds the
SSFR. If engine coolant reaches 107°C (225°F) the PCM grounds the high speed ground relay and
high speed fan relay. If the fan operates at high speed, the PCM de-energizes the high speed relay
and high speed ground relay when coolant temperature drops to approximately 101°C (214°F).
When coolant temperature drops to 101°C (214°F) the fan operates at low speed. The PCM
de-energizes the low speed relay when coolant temperature drops to approximately 93°C (199°F).
Also, when the air conditioning pressure switch closes, the fan operates at high speed. The air
conditioning switch closes at 285 psi ±10 psi. When air conditioning pressure drops approximately
40 psi, the pressure switch opens and the fan operates at low speed.
The SSFR is located on the left front inner frame -- just behind the radiator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Relays and Modules - Cooling System >
Radiator Cooling Fan Motor Relay > Component Information > Technical Service Bulletins > Page 2152
Radiator Cooling Fan Motor Relay: Testing and Inspection
Fan control is accomplished two ways. A pressure transducer on the compressor discharge line
sends a signal to the Powertrain Control Module (PCM) which will activate the fan. In addition to
this control, the fan is turned on by the temperature of the coolant which is sensed by the coolant
temperature sensor which sends the message to the PCM. The fan will not run during cranking
until the engine starts no matter what the coolant temperature is.
CAUTION: The solid state fan relay is attached to the left frame rail near the lower radiator support.
The relay bracket, and fastener are used to dissipate heat from the relay. Ensure the relay is
properly attached to prevent the following:
- Intermittent engine overheating.
- Relay "thermal" shutdown, or relay damage.
For Diagnosis See: Powertrain Management/Computers and Control Systems/Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code
Charts/Trouble Code (TC) Tests/TC-14A RAD Fan Control Relay Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2158
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2159
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2160
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2161
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2162
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Sensors and Switches - Cooling System >
Engine - Coolant Temperature Sensor/Switch > Temperature Sensor (Gauge) > Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Gauge Sending Unit
........................................................................................................................................................... 7
Nm (60 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Description and Operation
Temperature Gauge: Description and Operation
At idle with Air Conditioning off the temperature gauge will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to about 1/2 gauge travel. This is normal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Temperature Gauge: Initial Inspection and Diagnostic Overview
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See:
Instrument Panel, Gauges and Warning Indicators/Testing and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2171
Temperature Gauge: Component Tests and General Diagnostics
Temperature Diagnosis (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2172
Temperature Diagnosis (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2173
Temperature Diagnosis (Part 3 Of 3)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications
Thermostat: Specifications
TYPE
The engine cooling thermostats are a wax pellet driven, reverse poppet choke type.
OPERATING RANGES
Warm up They are designed to provide the fastest warm up possible by preventing leakage
through them and to guarantee a minimum engine operating temperature of 88 - 93°C (192 199°F).
Fully Warm Engine They also automatically reach wide open so they do not restrict flow to the
radiator as temperature of the coolant rises in hot weather to around 104°C (220°F). Above this
temperature the coolant temperature is controlled by the fan, the radiator, and the ambient
temperature, not the thermostat.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2177
Thermostat: Description and Operation
The engine cooling thermostats are a wax pellet driven, reverse poppet choke type. They are
designed to provide the fastest warm up possible by preventing leakage through them and to
guarantee a minimum engine operating temperature of 88 to 93°C (192 to 199°F). They also
automatically reach wide open so they do not restrict flow to the radiator as temperature of the
coolant rises in hot weather to around 104°C (220°F). Above this temperature the coolant
temperature is controlled by the fan, the radiator, and the ambient temperature, not the thermostat.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat, Engine Cooling > Component
Information > Specifications > Page 2178
Thermostat: Service and Repair
REMOVAL
1. Drain cooling system down below the thermostat level. Refer to Cooling System Draining.
Thermostat, Housing, And Water Box
2. Remove thermostat housing bolts and housing. 3. Remove thermostat, discard gasket and clean
both gasket sealing surfaces.
INSTALLATION
1. Place a new gasket (dipped in water) on the thermostat housing surface, center thermostat into
opening in the intake manifold water box. 2. Place housing and gasket over the thermostat, making
sure thermostat is in the recess provided. 3. Bolt housing to intake manifold, tighten bolts to 28 Nm
(250 inch lbs.). 4. Refill the cooling system to the proper level. Refer to Cooling System Refilling.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Thermostat Housing, Engine Cooling >
Component Information > Specifications
Thermostat Housing: Specifications
Bolts .....................................................................................................................................................
.................................................. 28 Nm (250 in. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Water Pump Bolts
Water Pump: Specifications
Water Pump Pulley Bolts 250 in.lb
Water Pump Mounting Bolts 105 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Specifications > Water Pump Bolts > Page 2186
Water Pump: Specifications Water Pump Pulley Bolts
Bolts .....................................................................................................................................................
.................................................. 28 Nm (250 in. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Description and Operation > Description and Operation
Water Pump: Description and Operation
The pump has a die cast aluminum body and a stamped steel impeller. It bolts directly to the chain
case cover, using an O-ring. for sealing. It is driven by the back surface of the Poly-V Drive Belt.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Description and Operation > Description and Operation > Page 2189
Water Pump: Description and Operation General Information
A quick test to tell whether the pump is working is to see if the heater warms properly. A defective
pump can not circulate heated coolant through the long heater hose. The water pump on all models
can be replaced without discharging the air conditioning system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Description and Operation > Page 2190
Water Pump: Testing and Inspection
Replace the water pump if it has any of the following defects. 1. Damage or cracks on the pump
body. 2. Coolant leaks; if the seal is leaking, this will be evident by traces of thick deposits of
greenish-brown dried glycol running down the pump body
and components below. A thin black stain below pump weep hole is considered normal operation.
3. Impeller rubs inside of chain case cover. 4. Excessively loose or rough turning bearing.
NOTE: It is normal for the water pump to weep a small amount of coolant from the weep hole
(black stain on water pump body). Do not replace the water pump if this condition exists. Replace
the water pump if a heavy deposit or a steady flow of green/brown engine coolant is evident on
water pump body from the weep hole (shaft seal failure). Be sure to perform a thorough analysis
before replacing water pump.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Cooling System > Water Pump > Component Information >
Description and Operation > Page 2191
Water Pump: Service and Repair
REMOVAL
1. Drain Cooling System. 2. Remove Poly-V Drive Belt. 3. Remove right front lower fender shield.
4. Remove pump pulley bolts and remove pulley.
Water Pump
5. Remove pump mounting screws. Remove water pump. 6. Remove and discard O-ring seal. 7.
Clean O-ring groove and O-ring surfaces on pump and chain case cover. Take care not to scratch
or gouge sealing surface.
INSTALLATION
Water Pump Body
1. Install new O-ring into groove. 2. Install pump to chain case cover. Torque screws to 12 Nm (105
inch lbs.) 3. Rotate pump by hand to check for freedom of movement. 4. Position pulley on pump.
Install screws and torque to 30 Nm (250 inch lbs.). 5. Install drive belt. 6. Install right front lower
fender shield. 7. Refill Cooling System. See Refilling Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter
Technical Service Bulletin # J25 Date: 091030
Recall - Replace Mopar(R) Value Line Catalytic Converter
October 2009
Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters
Models
1997 - 1999 (AN) Dodge Dakota
1998 - 1999 (BE) Dodge Ram Truck
1995 - 1999 (BR) Dodge Ram Truck
1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon
1996 - 1997 (LH) Chrysler LHS and Concorde
1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country
1998 (PL) Plymouth Neon
2003 (PT) Chrysler PT Cruiser
1998 - 1999 (TJ) Jeep(R) Wrangler
2001 (WJ) Jeep(R) Grand Cherokee
1994 (XJ) Jeep(R) Cherokee
1994 - 1995 (YJ) Jeep(R) Wrangler
1993 - 1998 (ZJ) Jeep(R) Grand Cherokee
NOTE:
This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter
installed.
IMPORTANT:
Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this
recall service on these vehicles before retail delivery. Involved vehicles can be determined by using
the VIP inquiry process.
Subject
During a prior service appointment, a Mopar Value Line catalytic converter was installed on about
47 of the above vehicles. These catalytic converters may fail an emissions inspection test.
Repair
The catalytic converter must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 2201
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to
record recall service completions and provide dealer payments.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 2202
Use the labor operation number and time allowances shown.
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Dealer Notification
To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab,
then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A
generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also
use the VIN list to follow up with all owners to schedule appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Customer Services Field Operations Chrysler Group LLC
Service Procedure
WARNING:
IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE
TORCH FLAME NEAR THE FUEL LINES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 2203
1. Raise and support the vehicle on an appropriate hoist.
2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration.
3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection.
4. Remove the exhaust clamp from the catalytic converter muffler connection.
5. Disconnect the oxygen sensor wiring.
6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal
becomes cherry red.
7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from
the exhaust pipe and the muffler.
8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter.
9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection.
10. Install the catalytic converter onto the exhaust pipe.
11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the
alignment slot.
12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp
nuts to 45 ft. lbs. (61 N.m).
13. Connect the oxygen sensor wiring.
14. Lower the vehicle from the hoist.
15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels.
16. Continue with Section B. Install the Authorized Modifications Label.
B. Install the Authorized Modifications Label:
Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the
Authorized Modifications Label. Then attach the label near the VECI label.
C. Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement
Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053)
and supply it to vehicle owners residing in the state of California for proof that this recall has been
performed when they renew the vehicle registration.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 2204
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter
Technical Service Bulletin # J25 Date: 091030
Recall - Replace Mopar(R) Value Line Catalytic Converter
October 2009
Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters
Models
1997 - 1999 (AN) Dodge Dakota
1998 - 1999 (BE) Dodge Ram Truck
1995 - 1999 (BR) Dodge Ram Truck
1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon
1996 - 1997 (LH) Chrysler LHS and Concorde
1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country
1998 (PL) Plymouth Neon
2003 (PT) Chrysler PT Cruiser
1998 - 1999 (TJ) Jeep(R) Wrangler
2001 (WJ) Jeep(R) Grand Cherokee
1994 (XJ) Jeep(R) Cherokee
1994 - 1995 (YJ) Jeep(R) Wrangler
1993 - 1998 (ZJ) Jeep(R) Grand Cherokee
NOTE:
This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter
installed.
IMPORTANT:
Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this
recall service on these vehicles before retail delivery. Involved vehicles can be determined by using
the VIP inquiry process.
Subject
During a prior service appointment, a Mopar Value Line catalytic converter was installed on about
47 of the above vehicles. These catalytic converters may fail an emissions inspection test.
Repair
The catalytic converter must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 2210
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to
record recall service completions and provide dealer payments.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 2211
Use the labor operation number and time allowances shown.
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Dealer Notification
To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab,
then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A
generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also
use the VIN list to follow up with all owners to schedule appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Customer Services Field Operations Chrysler Group LLC
Service Procedure
WARNING:
IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE
TORCH FLAME NEAR THE FUEL LINES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 2212
1. Raise and support the vehicle on an appropriate hoist.
2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration.
3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection.
4. Remove the exhaust clamp from the catalytic converter muffler connection.
5. Disconnect the oxygen sensor wiring.
6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal
becomes cherry red.
7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from
the exhaust pipe and the muffler.
8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter.
9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection.
10. Install the catalytic converter onto the exhaust pipe.
11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the
alignment slot.
12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp
nuts to 45 ft. lbs. (61 N.m).
13. Connect the oxygen sensor wiring.
14. Lower the vehicle from the hoist.
15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels.
16. Continue with Section B. Install the Authorized Modifications Label.
B. Install the Authorized Modifications Label:
Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the
Authorized Modifications Label. Then attach the label near the VECI label.
C. Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement
Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053)
and supply it to vehicle owners residing in the state of California for proof that this recall has been
performed when they renew the vehicle registration.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 2213
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 2214
Catalytic Converter: Service Precautions
NOTE: There is no regularly scheduled maintenance on the catalytic converter. If damaged, the
converter must be replaced.
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies,
extreme care should be taken with replacement parts. There are internal converter differences
required in some parts of the country.
REACTION
The combustion reaction caused by the catalyst releases additional heat in the exhaust system.
Causing temperature increases in the area of the reactor under severe operating conditions. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do
not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust
system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to
temperature increases caused by unburned fuel passing through the converter.
CATALYSTS
The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be
used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended
periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan
temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 2215
Catalytic Converter: Description and Operation
Three Way Catalyst (TWC)
PURPOSE
Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and
Oxides of Nitrogen (NOx)), by up to 90%.
OPERATION
Oxidation Reaction
As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation
(burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor
(H2O) and Carbon Dioxide (CO2).
This process no effect on NOx emissions.
Reduction Reaction
The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal
of oxygen), reaction.
OPERATING ENVIRONMENT
A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only
be achieved in a properly functioning feedback system with oxygen sensor.
The ideal converter operating temperature, for maximum emission reduction and long service life
is, 400°C - 800°C (750°F - 1500°F).
Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede
1400°C (2500°F), which can melt substrate material.
CONSTRUCTION
Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately
2 grams of platinum and rhodium).
CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material,
reducing or eliminating catalyst activity.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Catalytic Converter: Initial Inspection and Diagnostic Overview
VISUAL INSPECTION
Inspect Catalytic converter for external cracks. Repair or replace as necessary.
BACK PRESSURE CHECK
If excessive exhaust back pressure is suspected, eliminate the exhaust system as a cause. If
exhaust back pressure remains excessive with all mufflers disconnected, the catalytic converter
may be plugged.
LOOSE CORE CHECK
If the exhaust system rattles during engine operation, check the catalytic converter for a loose core.
With the vehicle raised (for access), tap the catalytic converter with a rubber mallet. If the converter
rattles, the core is loose and the converter must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2218
Catalytic Converter: Component Tests and General Diagnostics
Catalytic Converter Functional Test
NOTE: If all other emission systems are functioning correctly, but vehicle still has excessive tailpipe
emissions, the catalytic converter core may by contaminated. To check converter effectiveness,
perform the following test:
FUNCTIONAL CHECK
1. Warm the engine to normal operating temperature. 2. Run the engine at 2500 RPM for 30
seconds. 3. Using a pyrometer, measure the exhaust pipe temperature before and after the
catalytic converter. 4. Exhaust pipe temperature should be at least 100° F hotter at the converter
outlet than at the inlet. 5. If catalytic converter has little or no effect on exhaust temperature, the
core may be contaminated.
NOTE: If exhaust temperature exceeds 450° F, the engine may be running too lean. Repair the
lean running condition and recheck exhaust temperature before condemning the catalytic
converter.
At Oxygen Sensor Opening
Pressure Testing The Exhaust System at The Oxygen Sensor
NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire
up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel
system problems, then perform a visual inspection of the exhaust system. If the condition cannot
be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT
OXYGEN SENSOR OPENING
1. Carefully remove O2 sensor using proper tool. 2. Install Exhaust Backpressure Tester in place of
02 sensor. 3. With the engine at normal operating temperature and running at 2500 rpm, observe
the exhaust system backpressure reading on gauge. 4. If backpressure exceeds 1-1/4 psi (8.62
kPa), a restricted exhaust system is indicated. 5. Inspect the entire exhaust system for a collapsed
pipe, heat distress, or possible internal muffler failure. 6. If there are no obvious reasons for the
excessive backpressure, a restricted catalytic converter should be suspected, and replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Catalytic Converter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2219
NOTE: Prior to installing O2 sensor:
- Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap.
- Coat sensor threads with a nickel based anti-seize compound (Loctite 771-64 or equivalent). Do
not use graphite or other anti-seize compounds.
Using Manifold Vacuum Port
NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire
up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel
system problems, then perform a visual inspection of the exhaust system. If the condition cannot
be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT
MANIFOLD VACUUM PORT
1. With engine at normal operating temperature, connect a vacuum gauge to any convenient
manifold vacuum source. 2. Run engine at 1,000 rpm and record vacuum reading. 3. Increase rpm
slowly to 2,500 rpm, and note vacuum reading at a steady 2.500 rpm. 4. If vacuum at 2,500 rpm
decreases more than 3" Hg, from reading at 1000 rpm, the exhaust system should be inspected for
restrictions. 5. Disconnect exhaust pipe from engine and repeat Step 3 & 4. If vacuum still drops
more than 3" Hg, with exhaust disconnected, check for exhaust
manifold restriction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Technical Service Bulletins > Customer Interest for Exhaust Crossover Pipe: > 11-03-98 > Mar > 98 >
Exhaust System - Droning
Exhaust Crossover Pipe: Customer Interest Exhaust System - Droning
NO: 11-03-98
GROUP: Exhaust
DATE: Mar. 20, 1998
SUBJECT: Exhaust Drone
MODELS: 1998 (NS) Town & Country/Caravan/Voyager 1998 (GS) Chrysler Voyager (International
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Exhaust drone during: normal acceleration passing through 2100 RPM and 2800 RPM cruise at
65-70 MPH at 2100 RPM; light tip in at 70 MPH passing through 2,800 RPM; Wide Open Throttle
(WOT) passing through 4100 RPM.
DIAGNOSIS:
Test drive the vehicle at per the conditions described above and listen for an exhaust drone. If an
exhaust drone is heard, perform the Repair Procedure.
PARTS REQUIRED:
2 04448149 Gasket, Crossover Flange
1 06504127 Nut
1 06100219 Nut
1 06504374 Bolt
2 06502058 Bolt
REPAIR PROCEDURE:
This bulletin involves modifying the exhaust crossover pipe support bracket.
1. Open the hood.
2. Remove the bolt attaching the crossover pipe support bracket to the engine.
3. Remove the four bolts attaching the crossover pipe to the exhaust manifold and separate the
crossover pipe from the vehicle.
4. Mark the bolt slot in the support bracket of the crossover pipe as a guide to lengthen the slot 5
mm (3/16 in.) refer to Figure 1.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Technical Service Bulletins > Customer Interest for Exhaust Crossover Pipe: > 11-03-98 > Mar > 98 >
Exhaust System - Droning > Page 2228
5. Use a die grinder or file to enlarge the slot in the support bracket of the crossover pipe.
6. Discard the original crossover pipe flange gaskets.
7. Install the crossover pipe to exhaust manifolds using new flange gaskets, p/n 04448149.
8. Torque the crossover pipe to exhaust manifold attaching bolts to 54 Nm (40 ft. lbs.).
9. Torque the crossover pipe bracket to cylinder head attaching bolt to 54 Nm (40 ft. lbs.).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 11-10-01-90 0.7 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Crossover Pipe: > 11-03-98 > Mar >
98 > Exhaust System - Droning
Exhaust Crossover Pipe: All Technical Service Bulletins Exhaust System - Droning
NO: 11-03-98
GROUP: Exhaust
DATE: Mar. 20, 1998
SUBJECT: Exhaust Drone
MODELS: 1998 (NS) Town & Country/Caravan/Voyager 1998 (GS) Chrysler Voyager (International
Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION:
Exhaust drone during: normal acceleration passing through 2100 RPM and 2800 RPM cruise at
65-70 MPH at 2100 RPM; light tip in at 70 MPH passing through 2,800 RPM; Wide Open Throttle
(WOT) passing through 4100 RPM.
DIAGNOSIS:
Test drive the vehicle at per the conditions described above and listen for an exhaust drone. If an
exhaust drone is heard, perform the Repair Procedure.
PARTS REQUIRED:
2 04448149 Gasket, Crossover Flange
1 06504127 Nut
1 06100219 Nut
1 06504374 Bolt
2 06502058 Bolt
REPAIR PROCEDURE:
This bulletin involves modifying the exhaust crossover pipe support bracket.
1. Open the hood.
2. Remove the bolt attaching the crossover pipe support bracket to the engine.
3. Remove the four bolts attaching the crossover pipe to the exhaust manifold and separate the
crossover pipe from the vehicle.
4. Mark the bolt slot in the support bracket of the crossover pipe as a guide to lengthen the slot 5
mm (3/16 in.) refer to Figure 1.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Exhaust Crossover Pipe: > 11-03-98 > Mar >
98 > Exhaust System - Droning > Page 2234
5. Use a die grinder or file to enlarge the slot in the support bracket of the crossover pipe.
6. Discard the original crossover pipe flange gaskets.
7. Install the crossover pipe to exhaust manifolds using new flange gaskets, p/n 04448149.
8. Torque the crossover pipe to exhaust manifold attaching bolts to 54 Nm (40 ft. lbs.).
9. Torque the crossover pipe bracket to cylinder head attaching bolt to 54 Nm (40 ft. lbs.).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 11-10-01-90 0.7 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Crossover Pipe > Component
Information > Technical Service Bulletins > Page 2235
Exhaust Crossover Pipe: Specifications
Fasteners .............................................................................................................................................
...................................................... 54 Nm (40 ft. lbs.) Flange Fastener ..............................................
..................................................................................................................................... 28 Nm (250
inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications
Exhaust Manifold: Specifications
Exhaust Manifold Bolts 200 in.lb
Exhaust Manifold Flange (All) Fastener 250 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Specifications > Page 2239
Exhaust Manifold: Description and Operation
INTAKE/EXHAUST MANIFOLD
The intake manifold is a tuned two-piece semi-permanent mold aluminum casting with individual
primary runners leading from a plenum to the cylinders. The manifold is designed to boost torque in
the 3600 rpm range and contributes to the engine's broad, flat torque curve, which was desired for
excellent engine tractability, response and usable power output. The intake manifold is also cored
with upper level EGR passages for balanced cylinder to cylinder EGR distribution. The exhaust
manifolds are log type with a crossover and are attached directly to the cylinder heads. They are
made from nodular cast iron.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Service and Repair > Removal and Installation
Exhaust Manifold: Service and Repair Removal and Installation
REMOVAL
1. Disconnect battery negative cable. 2. Remove accessory drive belt. Refer to Accessory Drive
section located in Engine for procedure. 3. Remove generator. 4. Raise vehicle and disconnect
exhaust pipe from rear (cowl side) exhaust manifold at flex-joint. 5. Disconnect down stream
oxygen sensor connector. 6. Lower exhaust system to gain access to rear manifold. 7. Separate
EGR tube from rear manifold and disconnect Heated Oxygen Sensor lead wire. 8. Remove heat
shield from rear engine mount.
EGR Tube, Heated Oxygen Sensor And Generator/power Steering Strut
9. Remove Generator/Power Steering Support Strut.
10. Remove bolts attaching crossover pipe to manifold. 11. Disconnect up stream oxygen sensor
connector. 12. Remove bolts attaching rear manifold to cylinder head and remove manifold.
Heat Shield-Front
13. Lower vehicle and remove screws attaching front heat shield to front manifold.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Service and Repair > Removal and Installation > Page 2242
Crossover Pipe
14. Remove bolts fastening crossover pipe to front exhaust manifold and nuts fastening manifold to
cylinder head. Remove assemblies. 15. Inspect and clean manifold.
INSTALLATION
1. Install rear exhaust manifold and tighten attaching bolts to 23 Nm (200 inch lbs.). 2. Install
generator.
NOTE: Inspect crossover pipe fasteners for damage from heat and corrosion. Replace if
necessary.
3. Using new gasket attach crossover pipe to exhaust manifold and tighten bolts to 54 Nm (40 ft.
lbs.) and connect oxygen sensor lead. 4. Install EGR Tube and Generator/Power Steering Strut. 5.
Using new gaskets install front exhaust manifold and tighten attaching bolts to 23 Nm (200 inch
lbs.). 6. Attach exhaust crossover with a new gasket and tighten fasteners to 54 Nm (40 ft. lbs.). 7.
Connect up stream oxygen sensor connector. 8. Install exhaust system. 9. Attach exhaust pipe to
exhaust manifold using new gasket and tighten bolts to 28 Nm (250 inch lbs.).
10. Connect down stream oxygen sensor connector 11. Install front manifold heat shield and
tighten attaching screws to 12 Nm (105 inch lbs.). 12. Install accessory drive belt. Refer to
Accessory Drive section located in Engine for procedure. 13. Connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Manifold > Component Information
> Service and Repair > Removal and Installation > Page 2243
Exhaust Manifold: Service and Repair Cleaning and Inspection
INSPECTION
Check Exhaust Manifold Mounting
Inspect exhaust manifolds for damage or cracks and check distortion of the cylinder head mounting
surface and exhaust cross-over mounting surface with a straightedge and thickness gauge.
CLEANING
Remove the gasket material from the manifold surfaces (if equipped). Be careful not to gouge or
scratch the sealing surface.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe > Component Information >
Specifications
Exhaust Pipe: Specifications
Band Clamp (Torca) Fastener .............................................................................................................
...................................................... 75 Nm (55 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Pipe/Muffler Hanger > Component
Information > Specifications
Exhaust Pipe/Muffler Hanger: Specifications
Support Clamp Fastener .....................................................................................................................
................................................. 17 Nm (150 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Specifications
Heat Shield: Specifications
Bolts .....................................................................................................................................................
............................................... 12 Nm (105 inch lbs.) Fasteners .........................................................
..................................................................................................................................... 12 Nm (105
inch lbs.) Muffler Fastener ...................................................................................................................
................................................................... 2 Nm (23 inch lbs.) Toe Board Fastener .........................
........................................................................................................................................................ 2
Nm (23 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Heat Shield, Exhaust > Component
Information > Specifications > Page 2253
Heat Shield: Description and Operation
Heat Shields
Heat shields are needed to protect both the vehicle and the floor pan from the high temperatures
developed near the catalytic converter and muffler. Avoid application of rust prevention compounds
or undercoating materials to exhaust system floor pan heat shields on cars so equipped. Light over
spray near the edges is permitted. Application of coating will greatly reduce the efficiency of the
heat shields resulting in excessive floor pan temperatures and objectionable fumes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Technical Service Bulletins > Customer Interest for Muffler: > 11-05-98 > Apr > 98 > Muffler - Whistle Noise on Acceleration
Muffler: Customer Interest Muffler - Whistle Noise on Acceleration
NO: 11-05-98
GROUP: Exhaust
DATE: Apr. 10, 1998
SUBJECT: Whistle Noise During Acceleration
MODELS:
1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH A 3.0L,
3.3L OR 3.8L ENGINE AND SHORT WHEEL BASE (SWB) VEHICLES EQUIPPED WITH A 3.3L
CALIFORNIA EMISSIONS (SALES CODE EGA/NAE) OR 3.8L CALIFORNIA EMISSIONS (SALES
CODE EGH/NAE) ENGINE.
SYMPTOM/CONDITION:
Some vehicles may produce a high pitched whistle noise during Wide Open Throttle (WOT)
acceleration with engine speeds above 2500 RPM.
DIAGNOSIS:
Drive the vehicle until reaching normal operating temperature. With all accessories turned off, listen
for a high pitched whistle noise while accelerating at WOT with engine speeds above 2500 RPM. If
a whistle noise is heard, check the air cleaner box cover for complete sealing. If no air cleaner box
cover leaks are found, perform the Repair Procedure.
PARTS REQUIRED:
AR (1) 04809149 Muffler, 3.0L LWB
AR (1) 04809151 Muffler, 3.3L & 3.8L LWB
AR (1) 04809152 Muffler, 3.3L & 3.8L SWB (Sales Code NAE)
REPAIR PROCEDURE:
This bulletin involves replacing the muffler.
1. Using the procedure outlined on page 11-4 of the 1998 Town & Country, Caravan and Voyager
service manual (Publication No. 81-370-8105) replace the muffler.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 11-30-01-93 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Muffler: > 11-05-98 > Apr > 98 > Muffler - Whistle Noise on
Acceleration
Muffler: All Technical Service Bulletins Muffler - Whistle Noise on Acceleration
NO: 11-05-98
GROUP: Exhaust
DATE: Apr. 10, 1998
SUBJECT: Whistle Noise During Acceleration
MODELS:
1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO LONG WHEEL BASE (LWB) VEHICLES EQUIPPED WITH A 3.0L,
3.3L OR 3.8L ENGINE AND SHORT WHEEL BASE (SWB) VEHICLES EQUIPPED WITH A 3.3L
CALIFORNIA EMISSIONS (SALES CODE EGA/NAE) OR 3.8L CALIFORNIA EMISSIONS (SALES
CODE EGH/NAE) ENGINE.
SYMPTOM/CONDITION:
Some vehicles may produce a high pitched whistle noise during Wide Open Throttle (WOT)
acceleration with engine speeds above 2500 RPM.
DIAGNOSIS:
Drive the vehicle until reaching normal operating temperature. With all accessories turned off, listen
for a high pitched whistle noise while accelerating at WOT with engine speeds above 2500 RPM. If
a whistle noise is heard, check the air cleaner box cover for complete sealing. If no air cleaner box
cover leaks are found, perform the Repair Procedure.
PARTS REQUIRED:
AR (1) 04809149 Muffler, 3.0L LWB
AR (1) 04809151 Muffler, 3.3L & 3.8L LWB
AR (1) 04809152 Muffler, 3.3L & 3.8L SWB (Sales Code NAE)
REPAIR PROCEDURE:
This bulletin involves replacing the muffler.
1. Using the procedure outlined on page 11-4 of the 1998 Town & Country, Caravan and Voyager
service manual (Publication No. 81-370-8105) replace the muffler.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 11-30-01-93 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Muffler > Component Information >
Technical Service Bulletins > Page 2267
Muffler: Specifications
Insulator Mounting Bracket on Muffler to Body Bolts
....................................................................................................................... 28 Nm (250 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Engine, Cooling and Exhaust > Exhaust System > Exhaust Resonator > Component
Information > Specifications
Exhaust Resonator: Specifications
Insulator Mounting Bracket on Resonator to Body Bolts
.................................................................................................................... 28 Nm (250 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins
> BCM - Auto Lamp DTC Diagnostics
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component
Locations
Body Control Module: Component Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Locations > Component
Locations > Page 2280
Body Control Module Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2283
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2284
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2285
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2286
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2287
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2288
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2289
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2290
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2291
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2292
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2293
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2294
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2295
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2296
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2297
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2298
Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2299
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2300
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2301
Body Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2302
Body Control Module: Electrical Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2303
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2304
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2305
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2306
Exterior Lighting (Park Lamps)
Information Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2307
Instrument Cluster
Interior Lighting
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2308
Power Door Locks W/Remote Keyless Entry (RKE)
Power Door Locks W/O Remote Keyless Entry (RKE)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2309
Radio (CCD) Without Infinity Sound
Radio (CCD) With Infinity Sound
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2310
Vehicle Communications
Vehicle Theft Security System (VTSS)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2311
Windshield Wiper (Front)
Windshield Wiper (Rear)
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2312
Body Control Module (Part 1 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2313
Body Control Module (Part 2 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2314
Body Control Module (Part 3 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2315
Body Control Module (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2316
Body Control Module (Part 5 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2317
Body Control Module (Part 6 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram
Information and Instructions > Page 2318
Body Control Module (Part 7 Of 7)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions >
Technician Safety Information
Body Control Module: Technician Safety Information
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following approved procedures is very important to the safety of individuals performing
diagnostic tests.
DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and
can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED
or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive
wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Service Precautions >
Technician Safety Information > Page 2321
Body Control Module: Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will
severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with
rubbing alcohol.
Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the
test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear
view mirror or operate it yourself. Have an assistant available to operate the DRB.
Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes
or error messages may occur.
Servicing Sub-Assemblies
Some components of the body system are intended to be serviced in assembly only. Attempting to
remove or repair certain system sub-components may result in personal injury and/or improper
system operation. Only those components with approved repair and installation procedures in the
service manual should be serviced.
DRBIII Safety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious
or possibly fatal injury. Carefully read and understand the cautions and the specification limits.
^ Follow the vehicle manufacturer's service specifications at all times.
^ Do not use the DRB if it has been damaged.
^ Do not use the test leads if the insulation is damaged or if metal is exposed.
^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
^ Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
^ Do not exceed the limits shown in the table below:
FUNCTION/INPUT LIMIT
Volts 0 - 500 peak volts AC 0 - 500 volts DC
Ohms (resistance)* 0-1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated 0 - 10 kHz
Temperature -58 - 11000 F -50 - 600 C
* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered
circuit.
^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
^ Use caution when measuring voltage above 25v DC or 25v AC.
^ The circuit being tested must be protected by a 1OA fuse or circuit breaker.
^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure
circuits exceeding 10A.
^ When testing for the presence of voltage or current, make sure the meter is functioning correctly.
Take a reading of a known voltage or current before accepting a zero reading.
^ When measuring current, connect the meter in series with the load.
^ Disconnect the live test lead before disconnecting the common test lead.
^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid
measuring error form outside interference.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body
Code
Body Control Module: Application and ID Body Code
Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager
Body Code = NS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body
Code > Page 2324
Body Control Module: Application and ID Glossary of Terms
ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System
Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler
Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC
Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic
Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET
Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger
PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature
Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum
Fluorescent Display VTSS Vehicle Theft Security System
NOTE: The following terms are used interchangeably:
- Left Front (LF) Door & Driver (DR) Door
- Right Front (RF) Door and Passenger (PASS) Door
- "Gage" and "Gauge"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System
Body Control Module: Description and Operation Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2327
Body Control Module: Description and Operation Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2328
Body Control Module: Description and Operation Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2329
Body Control Module: Description and Operation Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2330
Body Control Module: Description and Operation
Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2331
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Compass Mini-Trip Computer (CMTC)
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Auto Headlamps
On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control
the exterior lamp operation by monitoring the mode selection switch located in the headlamp
control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal
from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light
levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Battery Protection: "Park & Headlamps"
This feature provides a battery protection scheme to avoid wearing down the battery if the
customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If
the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the
ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to
be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will
enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of
sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless
Entry (RKE) actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power on) will inhibit the battery protection routine from turning off the exterior lamps as described
above.
Exterior Headlamp Control
The headlamps and parklamps are illuminated via external relays which are controlled by the body
controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the
parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is
also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp
switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays.
The position of the hi-beam select switch will determine the mode of operation.
Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams
will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time.
Headlamp Time Delay
The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and
passengers security lighting when exiting the vehicle. This feature is only available on vehicles
equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by
sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and
parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp
delay. This 45 second window is new for the NS body. Once the headlamp delay has been
activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto
headlamp or the ignition switch changes states.
Identification of System
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2332
The vehicle systems that are part of the "body" system are:
- airbag system
- chimes
- compass/mini-trip
- courtesy lamps I panel dimming
- headlamp time delay
- illuminated entry
- radio (CCD)
- information center
- mechanical instrument cluster (MIC)
- power door locks
- remote keyless entry (RKE)
- vehicle communications
- vehicle theft security system (VTSS)
- wipers
Vehicles equipped with the highline body control module can be identified by the presence of the
vehicle theft security system (VTSS). Vehicles with the midline body control module may have a
compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or
illuminated entry. Vehicles with a base body control module will not have any of these features.
Introduction
Diagnostic procedures change every year. New diagnostic systems may be added; carryover
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO
BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These
tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover
all the necessary requirements to begin a logical diagnostic path for each repair. If there is a
trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you
to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are
used to direct you alphabetically to the specific systems.
NOTE: The following terms are used interchangeably:
Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door
Mechanical Instrument Cluster (MIC)
The body control module sends the angular position of the gauges, the status of all CCD indicator
lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus
when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped)
and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions;
all other MIC features work only when the ignition is in the "run" position. On transition of the
ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all
CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The
PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine
exceeds 450 rpm.
Power Door Lock System
When the body control module (BCM) receives an input for a lock request (door lock switch, RKE,
or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount
of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM
considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck,
the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates
in the same fashion as the lock signal. The door lock switches provide a variable amount of
resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond
to that command.
Other power door lock features:
Sliding Door Memory Lock
When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on
the lock relay as described above, and will turn it on again when all sliding doors are closed.
NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the
memory lock.
Door Lock Inhibit
When the key is in the ignition and in the off position, and any door except the rear liftgate is open,
all door lock switches are disabled. The unlock switches are still functional. This protects against
locking the vehicle with the keys still in the ignition.
Automatic Door Locks
This feature can be enabled or disabled by using either the DRBIII or customer programming
method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all
doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will
operate again once all doors are closed and the speed is above 15 MPH.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2333
RKE (Remote Keyless Entry) Interface
The body control module interfaces with the RKE receiver via a one-way serial bus interface. The
RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the
transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of
the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4
individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the
BCM will ground the interface wire thereby disabling the RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the on position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Radio System
There are three radio systems available this year that will be on the CCD bus. They are the RBR,
RBN and RAZ models. The main reason they are on the bus is because of the radio remote
controls in the steering wheel. They can control volume up/down, seek up, seek down and preset
station selections. These systems also communicate with the body control module and will set a
specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers
receive their signals from the quarter speakers. Depending on the manufacture some systems will
have a Front/Rear channel system and others will have a Left/Right channel system. If one of the
main quarter speaker audio circuits experiences a short, the other speakers on that channel will
also shut down until the circuit is repaired. The radio will also set a trouble code, which is
assessible with the DRB, indicating which channel is effected.
Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS)
This passive system is designed to protect against theft. The vehicle theft security system (VTSS)
is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for
unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park
and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after
closing them. The indicator lamp in the information center will flash for 15 seconds, showing that
arming is in progress. If no monitored systems are activated during this period, the system will arm.
If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain
steadily lit during the arming process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes.
Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it
means the alarm was activated. Check the vehicle for tampering.
Manual Override - The system will not arm if the doors are locked using the manual lock control (by
hand) or if the locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows:
1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with
the power lock switch. 4. Close the driver's door.
NOTE: After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may
be a problem with the system.
System initialization is accomplished by:
1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder
to unlock/disarm position.
Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all doors are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2334
been activated.
System Self-Test
NOTE: System self-test can be entered only with the DRB.
NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system
cannot be used in a vehicle that is not equipped with a vehicle theft security system.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
Shipping Mode
By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle.
The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse.
The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping
mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will
not operate until the IOD is reconnected or the ignition switch is turned to the run/start position.
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
System Coverage
These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth
Voyager vehicles equipped with either base, midline, or highline body control modules.
Airbag Trouble Code Descriptions
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of the trouble codes. It
is not necessary to perform all of the tests in the airbag section to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
"AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must
be performed. If more than one code exists, diagnostic priority should be given to the active
code(s).
Active diagnostic trouble codes for the airbag system are not permanent and will change the
moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes
are used as a diagnostic tool.
Active Codes
An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is
currently there every time the airbag control module checks that circuit/function. It is impossible to
erase an active code; active codes automatically erase by themselves when the reason for the
code has been corrected.
With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is
detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction
is present.
Stored Codes
An airbag trouble code becomes active and stored as soon as it is detected with the exception of
the Loss of Ignition Run Only code, which is an active code only.
A "stored" code indicates there was an active code present at some time. However, the code
currently may not be present as an active code, although another active code could be.
When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even
if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes
it was active, and the number of times the ignition has been cycled since the problem was last
detected.
The minimum time shown for any code will be one minute, even if the code was actually present for
less than one minute. Thus, the time shown for a code that was present for two minutes 13
seconds, for example, would be three minutes.
If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as
the malfunction exists. When and if the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2335
malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle
count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is
erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count
reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will
continue to be a stored code.
If a malfunction is not active while performing a diagnostic test procedure, the active code
diagnostic test will not locate the source of the problem. In this case, the stored code can indicate
an area to inspect.
If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire
harness and connectors. Recheck for codes periodically as you work through the system. This
procedure may uncover a malfunction that is difficult to locate.
Airbag Diagnostic Trouble Codes
The airbag control module may report any of the following diagnostic trouble codes.
For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer
- AECM Internal Diagnostic 2
- AECM Internal Diagnostic 1
- AECM Output Driver
- AECM Stored Energy
- Internal Diagnostic 3
- Incorrect AECM
For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open
- No CCD Communication
- Driver Squib Circuit Shorted
- Passenger Squib Circuit Open
- Driver Squib Term Shorted to Battery
- Passenger Squib Circuit Shorted
- Driver Squib Term Shorted to Ground
- Pass Squib Term Shorted to Battery
- Loss of Ignition Run Only
- Pass Squib Term Short to Ground
- Loss of Ignition Run/Start
- Warning Lamp Circuit Open
- Output Driver Not Tested
- Warning Lamp Circuit Shorted
Driver Squib Circuit Open
NAME OF CODE
Driver Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring open or high resistance in clockspring
- Driver side airbag module open
- Driver airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Driver Squib Circuit Shorted
NAME OF CODE
Driver Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring short
- Driver side airbag module short
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2336
- Driver airbag line 1 shorted to line 2
- Loose, or poor connector not completely connected
Driver Squib Term Shorted to Battery
NAME OF CODE
Driver Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to voltage
- Driver airbag line 2 short to voltage
- Faulty clockspring
- Faulty airbag control module
Driver Squib Term Shorted to Ground
NAME OF CODE
Driver Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to ground potential
- Driver airbag line 2 short to ground potential
- Faulty clockspring
- Faulty airbag control module
Loss of Ignition Run Only
NAME OF CODE
Loss of Ignition Run Only
NOTE: This code becomes active as soon as the condition is detected (this is not a stored code).
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Open ignition run circuit
- Open fuse
- Ignition run circuit short to ground
- Loose or poor connection at connector terminals
Loss of Ignition Run/Start
NAME OF CODE
Loss of Ignition Run/Start
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2337
- Open ignition run/start circuit
- Open fuse
- Ignition run/start circuit short to ground
- Loose or poor connection at connector terminals
Passenger Squib Circuit Open
NAME OF CODE
Passenger Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) open
- Passenger airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Passenger Squib Circuit Shorted
NAME OF CODE
Passenger Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) short
- Passenger airbag line 1 shorted to line 2
- Loose or poor connection at connector terminals
Pass Squib Term Shorted to Battery
NAME OF CODE
Pass Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to voltage
- Passenger airbag line 2 short to voltage
- Faulty airbag control module
Pass Squib Term Shorted to Ground
NAME OF CODE
Pass Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to ground potential
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2338
- Passenger airbag line 2 short to ground potential
- Faulty airbag control module
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NAME OF CODE
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or
during a lamp check.
SET CONDITION
With the voltage on, the airbag warning lamp driver circuit is other than expected.
POSSIBLE CAUSES
- Faulty warning lamp
- Open fused ignition switch output circuit to Information Center
- Airbag warning lamp driver circuit short to ground
- Airbag warning lamp driver circuit short to voltage
- Faulty information center printed circuit board
- Loose or poor connection at connector terminal
Output Driver Not Tested
NAME OF CODE
Output Driver Not Tested
WHEN MONITORED
At ignition on.
SET CONDITION
This code may set whenever another code is set due to any short to battery or short to ground
failure of the squib circuits. If all other squib codes have been repaired and this code appears
active by itself, the problem will be an internal failure of the airbag control module.
POSSIBLE CAUSES
- Short circuit to ground or to battery in either driver or passenger airbag lines
- Defective airbag control module
Trouble Code Testing Notes
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of trouble codes. It is
not necessary to perform all of the tests to diagnose an individual code.
The body control module will set a diagnostic trouble code if a monitored input is determined to be
malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the
trouble code condition is removed, the body control module will back out the diagnostic trouble
code if the trouble code condition remains cleared for twenty ignition cycles.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This
will direct you to the specific test(s) that must be performed.
ASB Message Not Received
NAME OF CODE
ASB Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from CAB every second. If this message is not received by the BCM
for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from CAB to BCM
Airbag Message Not Received
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2339
NAME OF CODE
Airbag Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from ACM every second. It this message is not received by the BCM
for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from ACM to BCM
Battery Power to Module Disconnected
NAME OF CODE
Battery Power to Module Disconnected
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
Battery power to the BCM is disconnected while the ignition is on.
THEORY OF OPERATION
The body control module checks battery input and determines if the battery is connected.
POSSIBLE CAUSES
- In shipping mode - IOD fuse missing
- Open wire
- Blown IOD fuse
EATX PRNDL Message Test Failed
NAME OF CODE
EATX PRNDL Message Test Failed
WHEN MONITORED
When engine is running.
SET CONDITION
The engine is running above 450 rpm and the body control module has not received a transmission
PRNDL message.
THEORY OF OPERATION
The body control module will monitor the CCD bus and look for the transmission PRNDL message
whenever the engine rpm is above 450.
POSSIBLE CAUSES
- Body Control module
- Transmission control module
- CCD bus failure
- Loss of power to transmission control module
EEPROM Checksum Failure
NAME OF CODE
EEPROM Checksum Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The sum of EEPROM constants does not equal the correct value.
THEORY OF OPERATION
By using a checksum, the BCM monitors the value of each programmable constant. The code is
set if any value is incorrect.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2340
- Body Control module
Front Wiper Park Switch CKT Open
NAME OF CODE
Front Wiper Park Switch Ckt Open
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Open wire
- Wiper motor
- Body Control module
Front Wiper Park Switch CKT-Shorted
NAME OF CODE
Front Wiper Park Switch Ckt-Shorted
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Shorted wire
- Wiper motor
- Body Control module
Fuel Level Sending Circuit Error
NAME OF CODE
Fuel Level Sending Circuit Error
WHEN MONITORED
With the ignition key on and battery voltage above 10 volts.
SET CONDITION
When the BCM senses an open or short on the fuel level sensor signal circuit.
THEORY OF OPERATION
The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on
fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be
set.
POSSIBLE CAUSES
- Open wire
- Shorted wire
- Fuel level sending unit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2341
- Body control module
Internal Module Test Failed
NAME OF CODE
Internal Module Test Failed
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The body control module performs an internal check and determines the body control module is not
functioning properly.
THEORY OF OPERATION
The body control module performs internal diagnostics on demand and determines if the body
control module microprocessor is functioning properly.
POSSIBLE CAUSES
- Body control module
Left Door Key CYL Arm SW Failure
NAME OF CODE
Left Door key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Key CYL Disarm SW Failure
NAME OF CODE
Left Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Lock Switch Failure
NAME OF CODE
Left Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2342
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Left Door Unlock Switch Failure
NAME OF CODE
Left Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Liftgate Key CYL Arm SW Failure
NAME OF CODE
Liftgate Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Key CYL Disarm SW Failure
NAME OF CODE
Liftgate Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2343
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Door Mux CKT Short to GND
NAME OF CODE
Liftgate Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (Liftgate Switch MUX)
- Body control module
LT Front Door Mux Circuit Short to GND
NAME OF CODE
LT Front Door MUX Circuit Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (LF Door Switch MUX)
- Body control module
No CCD Message From PCM
NAME OF CODE
No CCD Message From PCM
WHEN MONITORED
When the ignition is in the run or start position and battery voltage is above 10 volts.
SET CONDITION
The BCM looks for engine messages over the CCD bus and does not receive a message within a
2-second period.
THEORY OF OPERATION
The body control module will monitor the engine messages after the ignition has been turned on.
POSSIBLE CAUSES
- Body control module
- Powertrain control module
- CCD Bus failure
Rear Wiper Mux Circuit Error
NAME OF CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2344
Rear Wiper MUX Circuit Error
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts.
SET CONDITION
When the rear wiper MUX circuit senses a voltage above 5.0 volts.
THEORY OF OPERATION
The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The
CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level.
The voltage level will determine the wiper function to be performed. That level will be below 5.0
volts.
POSSIBLE CAUSES
- Circuit shorted to battery
- Open CCM ground circuit
Right Door Key CYL Arm SW Failure
NAME OF CODE
Right Door Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Key CYL Disarm SW Failure
NAME OF CODE
Right Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Lock Switch Failure
NAME OF CODE
Right Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2345
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
Right Door Unlock Switch Failure
NAME OF CODE
Right Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
RT Front Door Mux CKT Short to GND
NAME OF CODE
RT Front Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below .4 volts on the RF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (RF Door Switch MUX)
- Body control module
Horn Switch Failure
NAME OF CODE
Horn Switch Failure
WHEN MONITORED
Continuously with battery connected and IOD fuse installed.
SET CONDITION
The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering
wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more
than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The
horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to
cool down.
POSSIBLE CAUSES
- Shorted horn relay control circuit
- Defective horn switch
- Defective BCM
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2346
CCD Radio
NAME OF CODE
CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume
Down Switch (Stuck) Preset Switch (Stuck)
WHEN MONITORED
Anytime ignition is on and voltage is above 10.0 volts.
SET CONDITION
When a switch is held active for longer than 20 seconds.
THEORY OF OPERATION
The BCM monitors the control switches for an active condition and performs the required radio
function. When a switch is active for longer than 10 seconds, that switch function will be disabled
until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be
set.
POSSIBLE CAUSES
- Defective remote control switch
- Shorted radio control MUX circuit
Vehicle Communication
The body system consists of a combination of modules that communicate over the Chrysler
Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the
operation of vehicle components and circuits is relayed to the appropriate module(s). Each module
receives the same information about a component or circuit as the other modules do. This
significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus
plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
+ and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board
diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle
Communications section.
Any of the following bus failure messages may be displayed.
Short to Battery - Either or both of the bus wires are shorted to the battery potential.
Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential.
Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be
open.
Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together.
No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts.
Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their
normal 2.5 volts.
No Bus Bias - The bus system has lost connection with all modules that provide bias.
Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Description and Operation >
Airbag System > Page 2347
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias.
Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not
know why.
Wiper System
FRONT
The front wiper system provide the driver with normal wipe (low and high speeds), intermittent
wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a
resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on
position and the ignition is turned off, the wiper will continue to run until it reaches its park position.
Other front wiper system features:
Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay
of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay
time is doubled to provide a range time of from 1 second to 36 seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
REAR
The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics
Body Control Module: Component Tests and General Diagnostics
SELF DIAGNOSTIC TEST
To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the
TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to
the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in
the odometer windows (about five seconds) then release the
buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists
the code 999 (End Test) will momentarily appear.
INSTRUMENT CLUSTER DTC CHART
DTC .....................................................................................................................................................
.................................................... Description 110 ...............................................................................
.......................................................................................................... Memory Fault in cluster 111 .....
..............................................................................................................................................................
................... Calibration fault in cluster 905 .........................................................................................
................................................................................ No CCD bus messages from TCM 921 ..............
..............................................................................................................................................................
......... Odometer fault from BCM 940 ...................................................................................................
...................................................................... No CCD bus messages from PCM 999 ........................
..............................................................................................................................................................
.................... End of Codes
NOTE: For DTC testing see Condition Diagnostic Charts below.
CONDITIONS
Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Instrument Cluster Diagnosis
- Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Speedometer Diagnosis
- Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Tachometer Diagnosis
- Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Fuel Gauge Diagnosis
- Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Temperature Diagnosis
- Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Odometer Diagnosis
- Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis
- Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and
corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Calibration Table contains the proper calibration
points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If
any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III).
CLUSTER CALIBRATION TABLE
Speedometer .......................................................................................................................................
................................................. Calibration Point
1 ...........................................................................................................................................................
............................................... 0 mph (0 Km/h) 2 .................................................................................
..................................................................................................................... 20 mph (40 Km/h) 3 .......
..............................................................................................................................................................
................................. 55 mph (80 Km/h) 4 ...........................................................................................
.......................................................................................................... 75 mph(120 Km/h)
Tachometer .........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
............................................................... 0 rpm 2 ................................................................................
.................................................................................................................................... 1000 rpm 3 .....
..............................................................................................................................................................
................................................. 3000 rpm 4 ........................................................................................
............................................................................................................................ 6000 rpm
Fuel Gauge ..........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
......................................................... Empty(E) 2 .................................................................................
................................................................................................................................... 1/8 Filled 3 .......
..............................................................................................................................................................
............................................... 1/4 Filled 4 ...........................................................................................
............................................................................................................................ Full (F)
Temperature Gauge ............................................................................................................................
............................................... Calibration Point
1 ...........................................................................................................................................................
.......................................................... Cold (C) 2 .................................................................................
.............................................................................................................................. Low Normal 3 .......
..............................................................................................................................................................
......................................... High Normal 4 ............................................................................................
........................................................................................................................... Hot (H)
DIM TEST
When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays
will dim down. If the VF display brightness does
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 2350
no change, a problem exists in the cluster.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate
sequentially If a segment in the odometer does not illuminate normally, a problem exists in the
display.
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer window, each segment of the transmission range
indicator will illuminate sequentially. If a segment in the transmission range indicator does not
illuminate normally, a problem exists in the display board.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Component Tests and General Diagnostics > Page 2351
Body Control Module: Scan Tool Testing and Procedures
Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing
trouble codes, and other DRB functions.
DRBIII Error Messages
Under normal operation, the DRB will display one of only two error messages:
- User-Requested WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the scantool
manufacturer for information and assistance. This is a sample of such an error message display:
ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD
boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRBIII Does Not Power Up (Blank Screen)
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a
bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts
is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A
Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Page 2352
Body Control Module: Service and Repair
Body Control Module Location
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4.
Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting
bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control
Module downward to disengage guide studs on Junction Block from channels on BCM mounting
bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to
engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws
holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5.
Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom
of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker
reinforcement. 8. Connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection >
Page 2353
Body Control Module: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge (0-300 psi)
- Test Light
- Voltmeter
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Locations
Fig 1 Powertrain Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2359
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2360
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2361
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2362
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2363
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2364
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2365
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2366
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2367
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2368
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2369
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2370
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2371
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2372
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2373
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2374
Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2375
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2376
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2377
Powertrain Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2378
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2379
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Diagram Information and Instructions > Page 2380
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2381
Powertrain Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2382
Powertrain Control Module: Description and Operation
Fig 1 Powertrain Control Module
POWERTRAIN CONTROL MODULE (PCM)
The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input
signals from various switches and sensors that are referred to as PCM Inputs. Based on these
inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to
as PCM Outputs.
PCM Inputs: Air Conditioning Head Pressure
- Battery Voltage
- Brake Switch
- Camshaft Position Sensor
- Crankshaft Position Sensor
- Engine Coolant Temperature Sensor
- Heated Oxygen Sensors (Upstream and Downstream)
- Knock Sensor
- Manifold Absolute Pressure (MAP) Sensor
- SCI Receive
- Speed Control System Controls
- Throttle Position Sensor
- Transaxle Park/Neutral Position Switch (automatic transaxle)
- Transmission Control Module
- Vehicle Speed Sensor
PCM Outputs: Air Conditioning Clutch Relay
- Automatic Shutdown (ASD) Relay
- Data Link Connector
- Electric EGR Transducer
- Fuel Injectors
- Fuel Pump Relay
- Generator Field
- Idle Air Control Motor
- Ignition Coil
- Leak Detection Pump
- Malfunction Indicator (Check Engine) Lamp
- Proportional Purge Solenoid
- Radiator Fan Control Module
- Speed Control Solenoids
- Tachometer Output
- Torque Converter Clutch Solenoid (3 speed transmission)
- Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2383
Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air
conditioning and speed control systems. The PCM changes generator charge rate by adjusting the
generator field.
The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage
- Engine coolant temperature
- Exhaust gas content (oxygen sensors)
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
The PCM adjusts ignition timing based on the following inputs: Barometric pressure
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
The PCM also adjusts engine idle speed through the idle air control motor based on the following
inputs: Air conditioning select switch head pressure
- Brake switch
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
- Vehicle distance (speed)
Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump
relays are located in the Power Distribution Center (PDC).
The camshaft position sensor and crankshaft position sensor signals are sent to the PCM.
If the PCM does not receive both signals within approximately one second of engine cranking, it
deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut
off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump.
PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery
voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor
and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute
pressure sensor, throttle position sensor and engine coolant temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2384
Powertrain Control Module: Service and Repair
Fig 29 Power Distribution Center Retaining Screws
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29).
Fig 30 Battery Heat Shield
3. Remove heat shield from battery (Fig 30).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2385
Fig 31 Battery Clamp
4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle.
Fig 32 PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward
to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2386
Fig 33 PCM 40 Way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33).
Remove both way connectors.
Fig 34 PCM Removal/Installation
9. Remove 3 screws holding PCM to fender (Fig. 34).
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting
screws. 3. Install PDC bracket. 4. Install battery.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In
addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data
must be updated to enable starting.
For ABS and Air Bag systems:
ACTION:
1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules.
For SKIM theft alarm:
ACTION:
1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in
secured access mode, by using the appropriate PIN code for this vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component
Information > Diagrams > Page 2387
3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2393
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2394
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2395
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2396
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2397
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2398
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2399
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2400
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2401
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2402
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2403
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2404
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2405
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2406
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2407
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2408
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2409
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2410
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Diagram Information and Instructions > Page 2411
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Diagrams > Page 2412
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)]
> Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2415
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2420
Fuel Pump Relay: Diagrams
Fuel Pump Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2421
Fuel Pump Relay: Testing and Inspection
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 2422
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2428
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2429
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2430
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2431
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2432
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2433
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2434
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2435
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2436
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2437
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2438
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2439
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2440
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2441
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2442
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2443
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2444
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2445
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 2446
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 2447
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Relays and Modules - Powertrain Management > Relays and
Modules - Fuel Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 2450
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and
Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications >
Electrical Specifications > Page 2460
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page
2461
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2464
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2465
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2466
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2467
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2468
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2469
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2470
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2471
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2472
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2473
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2474
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2475
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2476
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2477
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2478
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2479
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2480
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2481
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2482
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2483
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2484
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2485
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2486
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2487
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page
2488
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2492
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2493
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2494
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2495
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component
Information > Specifications > Page 2496
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications >
Page 2500
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2503
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2504
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2505
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2506
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2507
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2508
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2509
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2510
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2511
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2512
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2513
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2514
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2515
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2516
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2517
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2518
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2519
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2520
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2521
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2522
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
2523
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
2524
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
2525
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page
2526
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Tank Sending Unit Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2533
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2534
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2535
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 2536
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
MAP Sensor ........................................................................................................................................
.......................................................... 4 Nm (35 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 2540
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 2541
Map Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 2542
Manifold Pressure/Vacuum Sensor: Description and Operation
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 2543
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Fig 92 Map Sensor Connector
NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and
appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3
(Fig. 92). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a
hot, neutral idle speed condition. If OK, go to next step.
- If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition.
- Repair as required.
3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43.
- If OK, go to next step.
- If not OK, repair as required.
4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON.
The voltage should be approximately 5 volts (4.5
to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor.
- If not OK, repair or replace the wire harness as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
> Page 2544
Manifold Pressure/Vacuum Sensor: Service and Repair
Fig 9 MAP Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake
manifold (Fig. 9). 3. Remove sensor from manifold.
INSTALLATION
- Reverse the above procedure for installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical
Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical
Specifications > Page 2549
Oxygen Sensor: Mechanical Specifications
Upstream 02S ......................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Downstream 02S .................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations
Oxygen Sensor: Component Locations
Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Oxygen Sensor
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component
Locations > Page 2552
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen
Sensor Connector
Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen
Sensor Connector > Page 2555
Downstream Heated Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2556
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 2557
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 2560
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection >
Powertrain Control Module Response Test > Page 2561
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground.
- The white wires in the sensor connector are the power and ground circuits for the heater.
- Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor
connector.
3. Resistance should be between 4 and 7 ohms.
- If not replace the sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
Fig 122 Oxygen Sensor Grommet Cover
WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen
sensor.
REMOVAL
1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122).
Fig 123 Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123).
Fig 124 Oxygen Sensor Removal & Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the
sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If
using original sensor, coat the threads
with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement > Page 2564
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair >
Downstream Oxygen Sensor Replacement > Page 2565
Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Fig 121 Upstream Heated Oxygen Sensor
The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121).
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when
servicing the oxygen sensor.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 2570
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2571
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2572
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2573
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2574
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 2575
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 2584
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 2585
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement >
Page 2586
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 2592
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb >
99 > Transmission Range Sensor - Production Change > Page 2593
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2598
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2599
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 2600
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change > Page 2606
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 >
Transmission Range Sensor - Production Change > Page 2607
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2610
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Transmission Solenoid and Pressure Switch Assembly > Page 2611
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2612
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2613
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2614
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information >
Locations > Page 2615
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2621
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2622
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2623
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2624
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2625
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2626
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2627
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2628
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2629
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2630
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2631
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2632
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2633
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2634
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2635
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2636
Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2637
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 2638
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Circuit Operation
Vehicle Speed Sensor: Description and Operation Circuit Operation
CIRCUIT OPERATION
If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM)
transmits the vehicle speed signal to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Circuit Operation > Page 2641
Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM
NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor.
CIRCUIT OPERATION
The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that
information to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Circuit Operation > Page 2642
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation
Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical
OPERATION
The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM.
The speed and distance signals, along with a closed throttle signal from the TPS, determine if a
closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired
MAP value.
- Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine
speed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation
> Page 2643
Vehicle Speed Sensor: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain
Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also
refer to the DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page
2648
Fuel Low Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 2652
Fuel Temperature Sensor Connector CNG
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component
Locations > Page 2657
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2658
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2659
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2660
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2661
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Fuel Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 2662
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 2668
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Specifications > Page 2669
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2672
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2673
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2674
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2675
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2676
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2677
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2678
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2679
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2680
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2681
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2682
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2683
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2684
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2685
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2686
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2687
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2688
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2689
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2690
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2691
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2692
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2693
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2694
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2695
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Camshaft Position Sensor > Component Information > Diagrams > Page 2696
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Specifications > Page 2700
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2703
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2704
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2705
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2706
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2707
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2708
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2709
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2710
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2711
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2712
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2713
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2714
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2715
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2716
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2717
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2718
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2719
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2720
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2721
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 2722
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2723
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2724
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2725
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Crankshaft Position Sensor > Component Information > Diagrams > Page 2726
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or
Cannot Be Removed > Page 2736
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not
Turn And/Or Cannot Be Removed > Page 2742
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 2743
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service
Bulletins > Page 2744
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2748
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2749
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2750
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Sensors and Switches - Powertrain Management > Sensors and
Switches - Ignition System > Knock Sensor > Component Information > Locations > Page 2751
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations > Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Pressure > Fuel
Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 2758
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air/Fuel Mixture >
System Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 2765
Idle Speed: Testing and Inspection
THROTTLE BODY MINIMUM AIR FLOW CHECK
Fig 97 Air Metering Fitting 6457
Fig 100 PCV Valve
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the
intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457
(0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from
the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link
connector.
10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The
following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
airflow is set correctly.
2.4L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 500-875 RPM
Above 1000 Miles 550-875 RPM
3.0L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 560-910 RPM
Above 1000 Miles 610-910 RPM
3.3L/3.8L Idle Specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Idle Speed > System
Information > Specifications > Page 2766
Odometer Reading Idle RPM
Below 1000 Miles 525-875 RPM
Above 1000 Miles 575-875 RPM
14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let
Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash
thoroughly after using cleaner.
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle
purge line. 18. Remove DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Fig 125 Air Inlet Resonator
REMOVAL
1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner
housing halves together.
Fig 126 Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing (Fig. 126).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Air Cleaner Housing >
Air Filter Element > Component Information > Service and Repair > Page 2771
Fig 127 Air Cleaner Element
4. Remove element from air cleaner housing (Fig. 127).
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Fuel Filter > Fuel
Pressure Release > System Information > Service and Repair > CNG Engine > Page 2777
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Firing Order >
Component Information > Specifications
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Number One Cylinder > Component Information > Locations
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Timing >
Timing Marks and Indicators > System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications
Ignition Cable: Specifications
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Specifications > Page 2791
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
PURPOSE
Transfer electrical current from the coil to the individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
CONSTRUCTION
The spark plug cables and spark plug boots are made from high temperature silicone materials.
Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust
manifold. The heat shields slide over the spark plug boots.
- The notches on the heat shields ensure the spark plug boot and shield twist together during spark
plug boot removal.
- They also identify proper heat shield installation on the boot for service.
- All spark plug cable leads are properly identified with cylinder numbers.
Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure.
- Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent
or missing.
- Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems.
- The bottom of the spark plug heat shield must make contact with the spark plug hex.
Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone
grease for greater sealing and to minimize boot bonding to the spark plug insulator.
The convoluted tubing on the rear plug cables are made of a high temperature plastic material.
Service Life Under normal driving conditions, the spark plug cables have a recommended service
life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for
severe driving conditions.
CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable
must not touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 2794
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter.
- Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
INSPECTION
Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good
condition.
Covers should fit tightly on the coil pack and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
Secondary Ignition Cable Resistance Test
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service and Repair > Replacing Cables
Ignition Cable: Service and Repair Replacing Cables
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
- Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
- Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can
damage the ignition cable conductor.
SPARK PLUG CABLES #3 AND #5
Removal
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug.
- Twist the boot slightly to break its seal with the plug and pull straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the
retaining bracket.
- Make sure that they are also detached from the rear retaining clip mounted on the rear of the
intake manifold.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
SPARK PLUG CABLE #1
Removal
1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the
upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug
boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal
with the plug and pull
straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
5. Wipe spark plug insulator clean with a dry cloth before installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service and Repair > Replacing Cables > Page 2797
6. Remove the cable from the retaining bracket.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt, refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Ignition Cable >
Component Information > Service and Repair > Replacing Cables > Page 2798
Ignition Cable: Service and Repair Cleaning Cables
Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables
dry. Check for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2802
Spark Plug: Service Precautions
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2803
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Specifications > Page 2804
Spark Plug: Description and Operation
Fig 3 Platinum Plug Pads
NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal driving conditions. The recommended
service life under severe conditions is 75,000 miles.
- A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3).
- Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator
damage during plug removal and installation.
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator.
CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs.
This would damage the platinum pads which would shorten spark plug life.
Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's
original spark plugs that have been determined good. -
Do not apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-seize compound does not make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark
plugs without reading the procedures.
Due to the engine packaging environment for this engine, extreme care should be used when
installing the spark plugs to avoid cross threading problems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2807
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2808
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2809
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2810
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2811
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2812
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Broken, Cracked or Chipped Insulator > Page 2813
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: -
In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Page 2814
Spark Plug: Adjustments
Setting Spark Plug Gap - Typical
Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or
oil fouled.
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Page 2815
Spark Plug: Service and Repair
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- Use extreme care when removing and installing the spark plug cables.
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
SPARK PLUG #3 AND #5
REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head.
3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield
assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break
the seal with the
plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
SPARK PLUG #1
REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts
from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark
plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly
slightly to break its seal with the
plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Spark Plug >
Component Information > Testing and Inspection > Page 2816
insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before
installation.
5. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure the coil or spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt, refer to Cooling System.
OTHER PLUGS
REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering
combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while
pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR: Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle
operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this
will allow deposit shifting in the combustion chamber to take place gradually and avoid plug
destroying splash fouling shortly after the plug change.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications
Compression Check: Specifications
Compression Ratio ..............................................................................................................................
........................................................................... 8.9:1 Minimum Compression ...................................
........................................................................................................................................ 689.5 kPa
(100 psi) Maximum Variation Between Cylinders ................................................................................
......................................................................................... 25%
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Compression Check >
System Information > Specifications > Page 2820
Compression Check: Testing and Inspection
The results of a cylinder compression pressure test can be utilized to diagnose several engine
malfunctions. Ensure the battery is completely charged and the engine starter motor is in good
operating condition. Otherwise the indicated compression pressures may not be valid for diagnosis
purposes. 1. Check engine oil level and add oil if necessary. 2. Drive the vehicle until engine
reaches normal operating temperature. Select a route free from traffic and other forms of
congestion, observe all
traffic laws, and accelerate through the gears several times briskly.
3. Remove all spark plugs from engine. As spark plugs are being removed, check electrodes for
abnormal firing indicators fouled, hot, oily, etc.
Record cylinder number of spark plug for future reference.
4. Disconnect coil wire from distributor and secure to good ground to prevent a spark from starting
a fire (Conventional Ignition System). For Direct
Ignition System (DIS) disconnect the coil connector.
5. Be sure throttle blade is fully open during the compression check. 6. Insert compression gage
adapter into the #1 spark plug hole in cylinder head. Crank engine until maximum pressure is
reached on gage. Record
this pressure as #1 cylinder pressure.
7. Repeat the previous step for all remaining cylinders. 8. Compression should not be less than
(689 kPa) 100 psi and not vary more than 25 percent from cylinder to cylinder. 9. If one or more
cylinders have abnormally low compression pressures, repeat the compression test.
10. If the same cylinder or cylinders repeat an abnormally low reading on the second compression
test, it could indicate the existence of a problem in
the cylinder in question. The recommended compression pressures are to be used only as a guide
to diagnosing engine problems. An engine should not be disassembled to determine the cause of
low compression unless some malfunction is present.
11. Clean or replace spark plugs as necessary and adjust gap as specified. Tighten to
specifications. 12. Test resistance of spark plug cables. 13. Test coil output voltage, primary and
secondary resistance. Replace parts as necessary. 14. Check fuel pump pressure at idle and
different RPM ranges. 15. The air filter elements should be replaced as specified, Lubrication and
Maintenance. 16. Inspect crankcase ventilation system. 17. Inspect and adjust accessory belt
drives. 18. Road test vehicle as a final test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Tune-up and Engine Performance Checks > Valve Clearance >
System Information > Specifications
Valve Clearance: Specifications
This engine is equipped with hydraulic valve lifters and are not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component
Information > Locations
A/C Pressure Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component
Information > Locations > Page 2828
A/C Pressure Switch Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > A/C Signal > Component
Information > Locations > Page 2829
A/C Signal: Description and Operation
PURPOSE
Powertrain Control Module (PCM) monitors engine load and A/C system pressure, and cycles the
A/C compressor clutch accordingly.
CONDITIONS
A/C or Defrost switch ON.
Combination valve, A/C low pressure and high pressure switches are closed.
OPERATION
Powertrain Control Module (PCM) receives an A/C selected signal.
- PCM engages A/C compressor clutch (by grounding clutch relay).
- PCM cycles compressor clutch depending on engine load and A/C system pressure.
- PCM maintains correct engine idle speed, through the Idle Air Control (IAC) Motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Battery Temperature Sensor >
Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Technical Service Bulletins > BCM - Auto Lamp DTC Diagnostics
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Component Locations
Body Control Module: Component Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Locations > Component Locations > Page 2839
Body Control Module Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2842
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2843
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2844
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2845
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2846
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2847
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2848
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2849
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2850
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2851
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2852
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2853
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2854
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2855
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2856
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2857
Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2858
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2859
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2860
Body Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2861
Body Control Module: Electrical Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2862
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2863
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2864
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2865
Exterior Lighting (Park Lamps)
Information Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2866
Instrument Cluster
Interior Lighting
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2867
Power Door Locks W/Remote Keyless Entry (RKE)
Power Door Locks W/O Remote Keyless Entry (RKE)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2868
Radio (CCD) Without Infinity Sound
Radio (CCD) With Infinity Sound
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2869
Vehicle Communications
Vehicle Theft Security System (VTSS)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2870
Windshield Wiper (Front)
Windshield Wiper (Rear)
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2871
Body Control Module (Part 1 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2872
Body Control Module (Part 2 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2873
Body Control Module (Part 3 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2874
Body Control Module (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2875
Body Control Module (Part 5 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2876
Body Control Module (Part 6 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Diagrams > Diagram Information and Instructions > Page 2877
Body Control Module (Part 7 Of 7)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service Precautions > Technician Safety Information
Body Control Module: Technician Safety Information
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following approved procedures is very important to the safety of individuals performing
diagnostic tests.
DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and
can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED
or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive
wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Service Precautions > Technician Safety Information > Page 2880
Body Control Module: Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will
severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with
rubbing alcohol.
Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the
test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear
view mirror or operate it yourself. Have an assistant available to operate the DRB.
Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes
or error messages may occur.
Servicing Sub-Assemblies
Some components of the body system are intended to be serviced in assembly only. Attempting to
remove or repair certain system sub-components may result in personal injury and/or improper
system operation. Only those components with approved repair and installation procedures in the
service manual should be serviced.
DRBIII Safety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious
or possibly fatal injury. Carefully read and understand the cautions and the specification limits.
^ Follow the vehicle manufacturer's service specifications at all times.
^ Do not use the DRB if it has been damaged.
^ Do not use the test leads if the insulation is damaged or if metal is exposed.
^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
^ Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
^ Do not exceed the limits shown in the table below:
FUNCTION/INPUT LIMIT
Volts 0 - 500 peak volts AC 0 - 500 volts DC
Ohms (resistance)* 0-1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated 0 - 10 kHz
Temperature -58 - 11000 F -50 - 600 C
* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered
circuit.
^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
^ Use caution when measuring voltage above 25v DC or 25v AC.
^ The circuit being tested must be protected by a 1OA fuse or circuit breaker.
^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure
circuits exceeding 10A.
^ When testing for the presence of voltage or current, make sure the meter is functioning correctly.
Take a reading of a known voltage or current before accepting a zero reading.
^ When measuring current, connect the meter in series with the load.
^ Disconnect the live test lead before disconnecting the common test lead.
^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid
measuring error form outside interference.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Application and ID > Body Code
Body Control Module: Application and ID Body Code
Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager
Body Code = NS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Application and ID > Body Code > Page 2883
Body Control Module: Application and ID Glossary of Terms
ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System
Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler
Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC
Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic
Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET
Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger
PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature
Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum
Fluorescent Display VTSS Vehicle Theft Security System
NOTE: The following terms are used interchangeably:
- Left Front (LF) Door & Driver (DR) Door
- Right Front (RF) Door and Passenger (PASS) Door
- "Gage" and "Gauge"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System
Body Control Module: Description and Operation Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2886
Body Control Module: Description and Operation Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2887
Body Control Module: Description and Operation Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2888
Body Control Module: Description and Operation Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2889
Body Control Module: Description and Operation
Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2890
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Compass Mini-Trip Computer (CMTC)
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Auto Headlamps
On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control
the exterior lamp operation by monitoring the mode selection switch located in the headlamp
control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal
from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light
levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Battery Protection: "Park & Headlamps"
This feature provides a battery protection scheme to avoid wearing down the battery if the
customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If
the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the
ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to
be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will
enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of
sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless
Entry (RKE) actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power on) will inhibit the battery protection routine from turning off the exterior lamps as described
above.
Exterior Headlamp Control
The headlamps and parklamps are illuminated via external relays which are controlled by the body
controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the
parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is
also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp
switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays.
The position of the hi-beam select switch will determine the mode of operation.
Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams
will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time.
Headlamp Time Delay
The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and
passengers security lighting when exiting the vehicle. This feature is only available on vehicles
equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by
sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and
parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp
delay. This 45 second window is new for the NS body. Once the headlamp delay has been
activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto
headlamp or the ignition switch changes states.
Identification of System
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2891
The vehicle systems that are part of the "body" system are:
- airbag system
- chimes
- compass/mini-trip
- courtesy lamps I panel dimming
- headlamp time delay
- illuminated entry
- radio (CCD)
- information center
- mechanical instrument cluster (MIC)
- power door locks
- remote keyless entry (RKE)
- vehicle communications
- vehicle theft security system (VTSS)
- wipers
Vehicles equipped with the highline body control module can be identified by the presence of the
vehicle theft security system (VTSS). Vehicles with the midline body control module may have a
compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or
illuminated entry. Vehicles with a base body control module will not have any of these features.
Introduction
Diagnostic procedures change every year. New diagnostic systems may be added; carryover
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO
BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These
tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover
all the necessary requirements to begin a logical diagnostic path for each repair. If there is a
trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you
to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are
used to direct you alphabetically to the specific systems.
NOTE: The following terms are used interchangeably:
Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door
Mechanical Instrument Cluster (MIC)
The body control module sends the angular position of the gauges, the status of all CCD indicator
lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus
when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped)
and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions;
all other MIC features work only when the ignition is in the "run" position. On transition of the
ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all
CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The
PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine
exceeds 450 rpm.
Power Door Lock System
When the body control module (BCM) receives an input for a lock request (door lock switch, RKE,
or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount
of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM
considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck,
the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates
in the same fashion as the lock signal. The door lock switches provide a variable amount of
resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond
to that command.
Other power door lock features:
Sliding Door Memory Lock
When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on
the lock relay as described above, and will turn it on again when all sliding doors are closed.
NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the
memory lock.
Door Lock Inhibit
When the key is in the ignition and in the off position, and any door except the rear liftgate is open,
all door lock switches are disabled. The unlock switches are still functional. This protects against
locking the vehicle with the keys still in the ignition.
Automatic Door Locks
This feature can be enabled or disabled by using either the DRBIII or customer programming
method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all
doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will
operate again once all doors are closed and the speed is above 15 MPH.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2892
RKE (Remote Keyless Entry) Interface
The body control module interfaces with the RKE receiver via a one-way serial bus interface. The
RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the
transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of
the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4
individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the
BCM will ground the interface wire thereby disabling the RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the on position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Radio System
There are three radio systems available this year that will be on the CCD bus. They are the RBR,
RBN and RAZ models. The main reason they are on the bus is because of the radio remote
controls in the steering wheel. They can control volume up/down, seek up, seek down and preset
station selections. These systems also communicate with the body control module and will set a
specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers
receive their signals from the quarter speakers. Depending on the manufacture some systems will
have a Front/Rear channel system and others will have a Left/Right channel system. If one of the
main quarter speaker audio circuits experiences a short, the other speakers on that channel will
also shut down until the circuit is repaired. The radio will also set a trouble code, which is
assessible with the DRB, indicating which channel is effected.
Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS)
This passive system is designed to protect against theft. The vehicle theft security system (VTSS)
is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for
unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park
and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after
closing them. The indicator lamp in the information center will flash for 15 seconds, showing that
arming is in progress. If no monitored systems are activated during this period, the system will arm.
If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain
steadily lit during the arming process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes.
Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it
means the alarm was activated. Check the vehicle for tampering.
Manual Override - The system will not arm if the doors are locked using the manual lock control (by
hand) or if the locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows:
1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with
the power lock switch. 4. Close the driver's door.
NOTE: After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may
be a problem with the system.
System initialization is accomplished by:
1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder
to unlock/disarm position.
Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all doors are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2893
been activated.
System Self-Test
NOTE: System self-test can be entered only with the DRB.
NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system
cannot be used in a vehicle that is not equipped with a vehicle theft security system.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
Shipping Mode
By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle.
The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse.
The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping
mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will
not operate until the IOD is reconnected or the ignition switch is turned to the run/start position.
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
System Coverage
These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth
Voyager vehicles equipped with either base, midline, or highline body control modules.
Airbag Trouble Code Descriptions
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of the trouble codes. It
is not necessary to perform all of the tests in the airbag section to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
"AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must
be performed. If more than one code exists, diagnostic priority should be given to the active
code(s).
Active diagnostic trouble codes for the airbag system are not permanent and will change the
moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes
are used as a diagnostic tool.
Active Codes
An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is
currently there every time the airbag control module checks that circuit/function. It is impossible to
erase an active code; active codes automatically erase by themselves when the reason for the
code has been corrected.
With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is
detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction
is present.
Stored Codes
An airbag trouble code becomes active and stored as soon as it is detected with the exception of
the Loss of Ignition Run Only code, which is an active code only.
A "stored" code indicates there was an active code present at some time. However, the code
currently may not be present as an active code, although another active code could be.
When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even
if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes
it was active, and the number of times the ignition has been cycled since the problem was last
detected.
The minimum time shown for any code will be one minute, even if the code was actually present for
less than one minute. Thus, the time shown for a code that was present for two minutes 13
seconds, for example, would be three minutes.
If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as
the malfunction exists. When and if the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2894
malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle
count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is
erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count
reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will
continue to be a stored code.
If a malfunction is not active while performing a diagnostic test procedure, the active code
diagnostic test will not locate the source of the problem. In this case, the stored code can indicate
an area to inspect.
If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire
harness and connectors. Recheck for codes periodically as you work through the system. This
procedure may uncover a malfunction that is difficult to locate.
Airbag Diagnostic Trouble Codes
The airbag control module may report any of the following diagnostic trouble codes.
For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer
- AECM Internal Diagnostic 2
- AECM Internal Diagnostic 1
- AECM Output Driver
- AECM Stored Energy
- Internal Diagnostic 3
- Incorrect AECM
For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open
- No CCD Communication
- Driver Squib Circuit Shorted
- Passenger Squib Circuit Open
- Driver Squib Term Shorted to Battery
- Passenger Squib Circuit Shorted
- Driver Squib Term Shorted to Ground
- Pass Squib Term Shorted to Battery
- Loss of Ignition Run Only
- Pass Squib Term Short to Ground
- Loss of Ignition Run/Start
- Warning Lamp Circuit Open
- Output Driver Not Tested
- Warning Lamp Circuit Shorted
Driver Squib Circuit Open
NAME OF CODE
Driver Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring open or high resistance in clockspring
- Driver side airbag module open
- Driver airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Driver Squib Circuit Shorted
NAME OF CODE
Driver Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring short
- Driver side airbag module short
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2895
- Driver airbag line 1 shorted to line 2
- Loose, or poor connector not completely connected
Driver Squib Term Shorted to Battery
NAME OF CODE
Driver Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to voltage
- Driver airbag line 2 short to voltage
- Faulty clockspring
- Faulty airbag control module
Driver Squib Term Shorted to Ground
NAME OF CODE
Driver Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to ground potential
- Driver airbag line 2 short to ground potential
- Faulty clockspring
- Faulty airbag control module
Loss of Ignition Run Only
NAME OF CODE
Loss of Ignition Run Only
NOTE: This code becomes active as soon as the condition is detected (this is not a stored code).
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Open ignition run circuit
- Open fuse
- Ignition run circuit short to ground
- Loose or poor connection at connector terminals
Loss of Ignition Run/Start
NAME OF CODE
Loss of Ignition Run/Start
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2896
- Open ignition run/start circuit
- Open fuse
- Ignition run/start circuit short to ground
- Loose or poor connection at connector terminals
Passenger Squib Circuit Open
NAME OF CODE
Passenger Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) open
- Passenger airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Passenger Squib Circuit Shorted
NAME OF CODE
Passenger Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) short
- Passenger airbag line 1 shorted to line 2
- Loose or poor connection at connector terminals
Pass Squib Term Shorted to Battery
NAME OF CODE
Pass Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to voltage
- Passenger airbag line 2 short to voltage
- Faulty airbag control module
Pass Squib Term Shorted to Ground
NAME OF CODE
Pass Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to ground potential
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2897
- Passenger airbag line 2 short to ground potential
- Faulty airbag control module
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NAME OF CODE
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or
during a lamp check.
SET CONDITION
With the voltage on, the airbag warning lamp driver circuit is other than expected.
POSSIBLE CAUSES
- Faulty warning lamp
- Open fused ignition switch output circuit to Information Center
- Airbag warning lamp driver circuit short to ground
- Airbag warning lamp driver circuit short to voltage
- Faulty information center printed circuit board
- Loose or poor connection at connector terminal
Output Driver Not Tested
NAME OF CODE
Output Driver Not Tested
WHEN MONITORED
At ignition on.
SET CONDITION
This code may set whenever another code is set due to any short to battery or short to ground
failure of the squib circuits. If all other squib codes have been repaired and this code appears
active by itself, the problem will be an internal failure of the airbag control module.
POSSIBLE CAUSES
- Short circuit to ground or to battery in either driver or passenger airbag lines
- Defective airbag control module
Trouble Code Testing Notes
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of trouble codes. It is
not necessary to perform all of the tests to diagnose an individual code.
The body control module will set a diagnostic trouble code if a monitored input is determined to be
malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the
trouble code condition is removed, the body control module will back out the diagnostic trouble
code if the trouble code condition remains cleared for twenty ignition cycles.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This
will direct you to the specific test(s) that must be performed.
ASB Message Not Received
NAME OF CODE
ASB Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from CAB every second. If this message is not received by the BCM
for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from CAB to BCM
Airbag Message Not Received
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2898
NAME OF CODE
Airbag Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from ACM every second. It this message is not received by the BCM
for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from ACM to BCM
Battery Power to Module Disconnected
NAME OF CODE
Battery Power to Module Disconnected
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
Battery power to the BCM is disconnected while the ignition is on.
THEORY OF OPERATION
The body control module checks battery input and determines if the battery is connected.
POSSIBLE CAUSES
- In shipping mode - IOD fuse missing
- Open wire
- Blown IOD fuse
EATX PRNDL Message Test Failed
NAME OF CODE
EATX PRNDL Message Test Failed
WHEN MONITORED
When engine is running.
SET CONDITION
The engine is running above 450 rpm and the body control module has not received a transmission
PRNDL message.
THEORY OF OPERATION
The body control module will monitor the CCD bus and look for the transmission PRNDL message
whenever the engine rpm is above 450.
POSSIBLE CAUSES
- Body Control module
- Transmission control module
- CCD bus failure
- Loss of power to transmission control module
EEPROM Checksum Failure
NAME OF CODE
EEPROM Checksum Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The sum of EEPROM constants does not equal the correct value.
THEORY OF OPERATION
By using a checksum, the BCM monitors the value of each programmable constant. The code is
set if any value is incorrect.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2899
- Body Control module
Front Wiper Park Switch CKT Open
NAME OF CODE
Front Wiper Park Switch Ckt Open
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Open wire
- Wiper motor
- Body Control module
Front Wiper Park Switch CKT-Shorted
NAME OF CODE
Front Wiper Park Switch Ckt-Shorted
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Shorted wire
- Wiper motor
- Body Control module
Fuel Level Sending Circuit Error
NAME OF CODE
Fuel Level Sending Circuit Error
WHEN MONITORED
With the ignition key on and battery voltage above 10 volts.
SET CONDITION
When the BCM senses an open or short on the fuel level sensor signal circuit.
THEORY OF OPERATION
The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on
fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be
set.
POSSIBLE CAUSES
- Open wire
- Shorted wire
- Fuel level sending unit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2900
- Body control module
Internal Module Test Failed
NAME OF CODE
Internal Module Test Failed
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The body control module performs an internal check and determines the body control module is not
functioning properly.
THEORY OF OPERATION
The body control module performs internal diagnostics on demand and determines if the body
control module microprocessor is functioning properly.
POSSIBLE CAUSES
- Body control module
Left Door Key CYL Arm SW Failure
NAME OF CODE
Left Door key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Key CYL Disarm SW Failure
NAME OF CODE
Left Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Lock Switch Failure
NAME OF CODE
Left Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2901
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Left Door Unlock Switch Failure
NAME OF CODE
Left Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Liftgate Key CYL Arm SW Failure
NAME OF CODE
Liftgate Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Key CYL Disarm SW Failure
NAME OF CODE
Liftgate Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2902
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Door Mux CKT Short to GND
NAME OF CODE
Liftgate Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (Liftgate Switch MUX)
- Body control module
LT Front Door Mux Circuit Short to GND
NAME OF CODE
LT Front Door MUX Circuit Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (LF Door Switch MUX)
- Body control module
No CCD Message From PCM
NAME OF CODE
No CCD Message From PCM
WHEN MONITORED
When the ignition is in the run or start position and battery voltage is above 10 volts.
SET CONDITION
The BCM looks for engine messages over the CCD bus and does not receive a message within a
2-second period.
THEORY OF OPERATION
The body control module will monitor the engine messages after the ignition has been turned on.
POSSIBLE CAUSES
- Body control module
- Powertrain control module
- CCD Bus failure
Rear Wiper Mux Circuit Error
NAME OF CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2903
Rear Wiper MUX Circuit Error
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts.
SET CONDITION
When the rear wiper MUX circuit senses a voltage above 5.0 volts.
THEORY OF OPERATION
The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The
CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level.
The voltage level will determine the wiper function to be performed. That level will be below 5.0
volts.
POSSIBLE CAUSES
- Circuit shorted to battery
- Open CCM ground circuit
Right Door Key CYL Arm SW Failure
NAME OF CODE
Right Door Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Key CYL Disarm SW Failure
NAME OF CODE
Right Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Lock Switch Failure
NAME OF CODE
Right Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2904
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
Right Door Unlock Switch Failure
NAME OF CODE
Right Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
RT Front Door Mux CKT Short to GND
NAME OF CODE
RT Front Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below .4 volts on the RF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (RF Door Switch MUX)
- Body control module
Horn Switch Failure
NAME OF CODE
Horn Switch Failure
WHEN MONITORED
Continuously with battery connected and IOD fuse installed.
SET CONDITION
The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering
wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more
than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The
horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to
cool down.
POSSIBLE CAUSES
- Shorted horn relay control circuit
- Defective horn switch
- Defective BCM
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2905
CCD Radio
NAME OF CODE
CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume
Down Switch (Stuck) Preset Switch (Stuck)
WHEN MONITORED
Anytime ignition is on and voltage is above 10.0 volts.
SET CONDITION
When a switch is held active for longer than 20 seconds.
THEORY OF OPERATION
The BCM monitors the control switches for an active condition and performs the required radio
function. When a switch is active for longer than 10 seconds, that switch function will be disabled
until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be
set.
POSSIBLE CAUSES
- Defective remote control switch
- Shorted radio control MUX circuit
Vehicle Communication
The body system consists of a combination of modules that communicate over the Chrysler
Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the
operation of vehicle components and circuits is relayed to the appropriate module(s). Each module
receives the same information about a component or circuit as the other modules do. This
significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus
plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
+ and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board
diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle
Communications section.
Any of the following bus failure messages may be displayed.
Short to Battery - Either or both of the bus wires are shorted to the battery potential.
Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential.
Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be
open.
Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together.
No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts.
Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their
normal 2.5 volts.
No Bus Bias - The bus system has lost connection with all modules that provide bias.
Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Description and Operation > Airbag System > Page 2906
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias.
Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not
know why.
Wiper System
FRONT
The front wiper system provide the driver with normal wipe (low and high speeds), intermittent
wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a
resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on
position and the ignition is turned off, the wiper will continue to run until it reaches its park position.
Other front wiper system features:
Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay
of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay
time is doubled to provide a range time of from 1 second to 36 seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
REAR
The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Component Tests and General Diagnostics
Body Control Module: Component Tests and General Diagnostics
SELF DIAGNOSTIC TEST
To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the
TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to
the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in
the odometer windows (about five seconds) then release the
buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists
the code 999 (End Test) will momentarily appear.
INSTRUMENT CLUSTER DTC CHART
DTC .....................................................................................................................................................
.................................................... Description 110 ...............................................................................
.......................................................................................................... Memory Fault in cluster 111 .....
..............................................................................................................................................................
................... Calibration fault in cluster 905 .........................................................................................
................................................................................ No CCD bus messages from TCM 921 ..............
..............................................................................................................................................................
......... Odometer fault from BCM 940 ...................................................................................................
...................................................................... No CCD bus messages from PCM 999 ........................
..............................................................................................................................................................
.................... End of Codes
NOTE: For DTC testing see Condition Diagnostic Charts below.
CONDITIONS
Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Instrument Cluster Diagnosis
- Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Speedometer Diagnosis
- Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Tachometer Diagnosis
- Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Fuel Gauge Diagnosis
- Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Temperature Diagnosis
- Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Odometer Diagnosis
- Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis
- Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and
corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Calibration Table contains the proper calibration
points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If
any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III).
CLUSTER CALIBRATION TABLE
Speedometer .......................................................................................................................................
................................................. Calibration Point
1 ...........................................................................................................................................................
............................................... 0 mph (0 Km/h) 2 .................................................................................
..................................................................................................................... 20 mph (40 Km/h) 3 .......
..............................................................................................................................................................
................................. 55 mph (80 Km/h) 4 ...........................................................................................
.......................................................................................................... 75 mph(120 Km/h)
Tachometer .........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
............................................................... 0 rpm 2 ................................................................................
.................................................................................................................................... 1000 rpm 3 .....
..............................................................................................................................................................
................................................. 3000 rpm 4 ........................................................................................
............................................................................................................................ 6000 rpm
Fuel Gauge ..........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
......................................................... Empty(E) 2 .................................................................................
................................................................................................................................... 1/8 Filled 3 .......
..............................................................................................................................................................
............................................... 1/4 Filled 4 ...........................................................................................
............................................................................................................................ Full (F)
Temperature Gauge ............................................................................................................................
............................................... Calibration Point
1 ...........................................................................................................................................................
.......................................................... Cold (C) 2 .................................................................................
.............................................................................................................................. Low Normal 3 .......
..............................................................................................................................................................
......................................... High Normal 4 ............................................................................................
........................................................................................................................... Hot (H)
DIM TEST
When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays
will dim down. If the VF display brightness does
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2909
no change, a problem exists in the cluster.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate
sequentially If a segment in the odometer does not illuminate normally, a problem exists in the
display.
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer window, each segment of the transmission range
indicator will illuminate sequentially. If a segment in the transmission range indicator does not
illuminate normally, a problem exists in the display board.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Component Tests and General Diagnostics > Page 2910
Body Control Module: Scan Tool Testing and Procedures
Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing
trouble codes, and other DRB functions.
DRBIII Error Messages
Under normal operation, the DRB will display one of only two error messages:
- User-Requested WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the scantool
manufacturer for information and assistance. This is a sample of such an error message display:
ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD
boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRBIII Does Not Power Up (Blank Screen)
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a
bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts
is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A
Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Page 2911
Body Control Module: Service and Repair
Body Control Module Location
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4.
Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting
bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control
Module downward to disengage guide studs on Junction Block from channels on BCM mounting
bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to
engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws
holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5.
Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom
of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker
reinforcement. 8. Connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Body Control Module >
Component Information > Testing and Inspection > Page 2912
Body Control Module: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge (0-300 psi)
- Test Light
- Voltmeter
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Brake Signal > Component
Information > Description and Operation
Brake Signal: Description and Operation
LOCATION
Sensor mounted on brake pedal support bracket.
PURPOSE
Powertrain Control Module (PCM) uses switch input to control idle speed and speed control.
OPERATION
PCM vents speed control system vacuum and turns speed control system OFF when appraised of
a brake switch actuation.
PCM prevents engine stall during rapid decel, by actuating Idle Air Control (IAC) motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Electrical Specifications > Page 2920
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Specifications > Page 2921
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2924
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2925
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2926
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2927
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2928
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2929
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2930
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2931
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2932
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2933
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2934
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2935
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2936
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2937
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2938
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2939
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2940
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2941
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2942
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2943
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2944
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2945
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2946
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2947
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Camshaft Position Sensor >
Component Information > Diagrams > Page 2948
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2952
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2953
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2954
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2955
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Coolant Temperature
Sensor/Switch (For Computer) > Component Information > Specifications > Page 2956
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Specifications > Page 2960
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2963
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2964
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2965
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2966
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2967
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2968
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2969
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2970
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2971
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2972
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2973
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2974
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2975
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2976
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2977
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2978
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2979
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2980
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2981
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 2982
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2983
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2984
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2985
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Crankshaft Position Sensor >
Component Information > Diagrams > Page 2986
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Locations > Page 2990
Data Link Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Description and Operation > Data Link Connector
Data Link Connector: Description and Operation Data Link Connector
CIRCUIT OPERATION
Circuit M1 from fuse 10 in the Power Distribution Center (PDC) supplies battery voltage to the data
link connector. A twisted pair of wires, circuits D1 and D2 connect the data link connector to the
CCD Bus.
Ground circuit Z11 splices to the data link connector. Circuit Z11 splices to circuit Z12. Both circuit
connect to the PCM. Circuit Z2 also connects to the data link connector.
Circuit D20 connects to cavity 75 of the PCM. Circuit D20 is the SCI receive circuit for the PCM.
Circuit D21 connects to cavity 65 of the PCM. Circuit D21 is the SCI transmit circuit for the PCM.
The D21 circuit splices to the Transmission Control Module (TCM).
The D6 circuit also connects between the data link connector and the TCM.
Helpful Information Circuit Z12 also supplies ground for the PCM high current drivers and has the
same termination point as circuit Z11.
If the system loses ground for circuits Z11 and Z12, the vehicle will not operate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Description and Operation > Data Link Connector > Page 2993
Data Link Connector: Description and Operation SCI Receive
The SCI receive circuit is used as a communication path for the scan tool. The scan tool receives
data through this circuit.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Data Link Connector >
Component Information > Description and Operation > Data Link Connector > Page 2994
Data Link Connector: Description and Operation SCI Transmit
PURPOSE
Powertrain Control Module (PCM) sends data to the scan tool through this circuit, including;
- Sensor input values
- Diagnostic Trouble Codes (DTC's) stored in memory
- Last deactivation cause (i.e.. speed control last shut off by; speed control switch, brake switch or
no crank sensor signal).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer
> Component Information > Locations
EGR Backpressure Transducer: Locations
EGR Solenoid And Valve
Electric EGR Transducer (EET)
EGR System
Mounted near the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer
> Component Information > Locations > Page 2998
EGR Backpressure Transducer: Description and Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR
valve control nipple, (depending on engine load conditions).
OPERATION
Transducer is supplied ported vacuum through the solenoid.
Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no
vacuum is applied to the EGR valve.
- When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and
maximum vacuum is applied to the EGR valve.
- When exhaust backpressure is present, but not great enough to close the vacuum bleed valve
completely, the vacuum applied to the EGR valve varies with the backpressure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer
> Component Information > Locations > Page 2999
EGR Backpressure Transducer: Testing and Inspection
TESTING ELECTRICAL SOLENOID PORTION OF VALVE
This is not to be used as a complete test of the EGR system.
Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to
the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly
Fig 4 EGR System
TESTING VACUUM TRANSDUCER PORTION OF VALVE
NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure
side of the valve has ruptured or is leaking. The second part of the test will determine if engine
vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used
as a complete test of the EGR system.
1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2.
Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If
vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to
next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the
EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to
operating temperature.
- Hold engine speed at approximately 1,500 rpm.
9. Check for steady engine vacuum (full-manifold) at this hose.
10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as
necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet
fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4)
on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical
connector (Fig. 4) at the valve control.
- This will simulate an open circuit (no ground from the PCM) at the valve.
15. Start the engine and bring to operating temperature. 16. Hold the engine speed to
approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting.
- To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present
at valve.
- It must be high enough to hold the bleed valve in the transducer portion of the valve closed.
- Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some
exhaust back-pressure while observing the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer
> Component Information > Locations > Page 3000
vacuum gauge.
- Heavy gloves should be worn.
CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to
components or overheating may result.
17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum
outlet fitting.
- Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low.
- This low reading is normal.
- At idle speed, the gauge reading will be erratic.
- This is also normal.
18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting,
replace the valve.
NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > EGR Backpressure Transducer
> Component Information > Locations > Page 3001
EGR Backpressure Transducer: Service and Repair
EGR Mounting
REMOVAL
1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for
any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove
transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for
signs of leakage or cracks.
INSTALLATION
1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install
transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and
electrical connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Locations
Fig 1 Powertrain Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3007
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3008
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3009
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3010
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3011
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3012
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3013
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3014
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3015
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3016
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3017
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3018
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3019
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3020
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3021
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3022
Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3023
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3024
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3025
Powertrain Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3026
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3027
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Diagram Information and Instructions > Page 3028
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3029
Powertrain Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3030
Powertrain Control Module: Description and Operation
Fig 1 Powertrain Control Module
POWERTRAIN CONTROL MODULE (PCM)
The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input
signals from various switches and sensors that are referred to as PCM Inputs. Based on these
inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to
as PCM Outputs.
PCM Inputs: Air Conditioning Head Pressure
- Battery Voltage
- Brake Switch
- Camshaft Position Sensor
- Crankshaft Position Sensor
- Engine Coolant Temperature Sensor
- Heated Oxygen Sensors (Upstream and Downstream)
- Knock Sensor
- Manifold Absolute Pressure (MAP) Sensor
- SCI Receive
- Speed Control System Controls
- Throttle Position Sensor
- Transaxle Park/Neutral Position Switch (automatic transaxle)
- Transmission Control Module
- Vehicle Speed Sensor
PCM Outputs: Air Conditioning Clutch Relay
- Automatic Shutdown (ASD) Relay
- Data Link Connector
- Electric EGR Transducer
- Fuel Injectors
- Fuel Pump Relay
- Generator Field
- Idle Air Control Motor
- Ignition Coil
- Leak Detection Pump
- Malfunction Indicator (Check Engine) Lamp
- Proportional Purge Solenoid
- Radiator Fan Control Module
- Speed Control Solenoids
- Tachometer Output
- Torque Converter Clutch Solenoid (3 speed transmission)
- Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3031
Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air
conditioning and speed control systems. The PCM changes generator charge rate by adjusting the
generator field.
The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage
- Engine coolant temperature
- Exhaust gas content (oxygen sensors)
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
The PCM adjusts ignition timing based on the following inputs: Barometric pressure
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
The PCM also adjusts engine idle speed through the idle air control motor based on the following
inputs: Air conditioning select switch head pressure
- Brake switch
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
- Vehicle distance (speed)
Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump
relays are located in the Power Distribution Center (PDC).
The camshaft position sensor and crankshaft position sensor signals are sent to the PCM.
If the PCM does not receive both signals within approximately one second of engine cranking, it
deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut
off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump.
PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery
voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor
and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute
pressure sensor, throttle position sensor and engine coolant temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3032
Powertrain Control Module: Service and Repair
Fig 29 Power Distribution Center Retaining Screws
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29).
Fig 30 Battery Heat Shield
3. Remove heat shield from battery (Fig 30).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3033
Fig 31 Battery Clamp
4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle.
Fig 32 PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward
to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3034
Fig 33 PCM 40 Way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33).
Remove both way connectors.
Fig 34 PCM Removal/Installation
9. Remove 3 screws holding PCM to fender (Fig. 34).
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting
screws. 3. Install PDC bracket. 4. Install battery.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In
addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data
must be updated to enable starting.
For ABS and Air Bag systems:
ACTION:
1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules.
For SKIM theft alarm:
ACTION:
1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in
secured access mode, by using the appropriate PIN code for this vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Powertrain Control Module <-->
[Engine Control Module] > Component Information > Diagrams > Page 3035
3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Fuel Level Sensor >
Component Information > Diagrams
Fuel Tank Sending Unit Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications
Idle Air Control Motor ...........................................................................................................................
....................................................... 2 Nm (18 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations
Idle Speed/Throttle Actuator - Electronic: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3044
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3047
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3048
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3049
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3050
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3051
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3052
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3053
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3054
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3055
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3056
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3057
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3058
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3059
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3060
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3061
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3062
Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3063
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3064
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3065
Idle Air Control Moor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3066
Idle Air Control Motor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3067
Idle Speed/Throttle Actuator - Electronic: Description and Operation
PURPOSE
Maintains optimum idle speed under varying engine loads.
Prevents deceleration die out.
OPERATION
Powertrain Control Module (PCM) calculates proper idle speed using information from throttle
position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches.
PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body.
Prevents decel die out by increasing air flow when throttle is closed suddenly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3068
Idle Speed/Throttle Actuator - Electronic: Testing and Inspection
NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool.
CAUTION: Proper safety precautions must be taken when testing the IAC motor.
- Set the parking brake and block the drive wheels
- Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust
components
- Provide proper ventilation while operating the engine
- Always return the engine idle speed to normal before disconnecting the exerciser tool.
- Follow scan tool manufacturer's instructions for testing the IAC motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3069
Idle Speed/Throttle Actuator - Electronic: Service and Repair
Fig 109 Servicing Idle Air Control Motor
NOTE: When servicing throttle body components, always reassemble components with new
0-rings and seals where applicable.
- Never use lubricants on 0-rings or seals, damage may result.
- If assembly of component is difficult, use water to aid assembly.
- Use care when removing hoses to prevent damage to hose or hose nipple.
REMOVAL
1. Disconnect negative cable from battory; 2. Remove electrical connector from idle air control
motor. 3. Remove idle air control motor mounting screws (Fig. 109). 4. Remove motor from throttle
body. Ensure the 0-ring is removed with the motor.
INSTALLATION
1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the DRB
Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.)
2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten
screws to 2 Nm (17 in lb) torque. 4. Connect electrical connector to idle air control motor. 5.
Connect negative cable to battery
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > Vehicle Communication
Information Bus: Description and Operation Vehicle Communication
The body system consists of a combination of modules that communicate over the CCD (Chrysler
Collision Detection multiplex system) bus. Through the CCD bus, information about the operation
of vehicle components and circuits is relayed to the appropriate module(s). Each module receives
the same information about a component or circuit as the other modules do. This significantly
reduces the complexity of the wiring in the vehicle and the size of the wiring harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has higher priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus
plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
+ and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: Communication over the bus is essential to the proper operation of the vehicle on-board
diagnostic systems and the scan tool. Problems with the operation of the bus or scan tool must be
corrected before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle
Communications section.
Any of the following bus failure messages may be displayed:
Short to Battery - Either or both of the bus wires are shorted to the battery potential. Short to 5 Volts
- Either or both of the bus wires are shorted to a 5-volt potential. Short to Ground - Either or both of
the bus wires are shorted to ground or a specific ground may be open. Bus (+) & Bus (-) Shorted
Together - The two bus wires are shorted together. No Termination - The bus system has lost
connection with all of its terminators. Bus Bias Level Too Low - Either or both of the bus wire
potentials are significantly below their normal 2.5 volts. Bus Bias Level Too High - Either or both of
the bus wire potentials are significantly above their normal 2.5 volts. No Bus Bias - The bus system
has lost connection with all modules that provide bias. Bus (+) Open - The bus (+) wire has lost
connection with termination and/or bias. Bus (-) Open - The bus (-) wire has lost connection with
termination and/or bias. Not Receiving Bus Messages Correctly - The DRB cannot communicate
over the bus and does not know why.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Information Bus > Component
Information > Description and Operation > Vehicle Communication > Page 3074
Information Bus: Description and Operation CCD Bus Circuit Operation
CIRCUIT OPERATION
The CCD Bus is used to supply all of the communications between the Body Control Module
(BCM), other vehicle controllers and the instrument cluster. The bus wires are a twisted pair. There
are two different circuits used for the bus.
The positive side of the bus wire is accomplished on the D1 circuit. and the negative is on the D2
circuit.
To allow the Body Control Module (BCM) to communicate and control various vehicle functions the
BCM uses the CCD bus. This is a twisted pair of wires that connects to the other modules and
controllers. Circuits D1 and D2 are used for the communication interface.
Circuit D1 is used for the CCD (+), and circuit D2 is used for CCD (-).
The CCD BUS and the universal data link connector are used for access to the diagnostic
capabilities of the radio. Circuits D1 and D2 are used.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3078
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3079
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3080
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Knock Sensor > Component
Information > Locations > Page 3081
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3087
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3088
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3089
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3090
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3091
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3092
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3093
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3094
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3095
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3096
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3097
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3098
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3099
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3100
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3101
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3102
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3103
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3104
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3105
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3106
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay > Page 3109
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code
Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble
Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
MAP Sensor ........................................................................................................................................
.......................................................... 4 Nm (35 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 3113
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 3114
Map Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 3115
Manifold Pressure/Vacuum Sensor: Description and Operation
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 3116
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Fig 92 Map Sensor Connector
NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and
appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3
(Fig. 92). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a
hot, neutral idle speed condition. If OK, go to next step.
- If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition.
- Repair as required.
3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43.
- If OK, go to next step.
- If not OK, repair as required.
4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON.
The voltage should be approximately 5 volts (4.5
to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor.
- If not OK, repair or replace the wire harness as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Manifold Pressure/Vacuum
Sensor > Component Information > Specifications > Page 3117
Manifold Pressure/Vacuum Sensor: Service and Repair
Fig 9 MAP Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake
manifold (Fig. 9). 3. Remove sensor from manifold.
INSTALLATION
- Reverse the above procedure for installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Specifications > Electrical Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Specifications > Electrical Specifications > Page 3122
Oxygen Sensor: Mechanical Specifications
Upstream 02S ......................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Downstream 02S .................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations
Oxygen Sensor: Component Locations
Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Oxygen Sensor
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Locations > Component Locations > Page 3125
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Upstream Oxygen Sensor Connector
Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Upstream Oxygen Sensor Connector > Page 3128
Downstream Heated Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 3129
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Diagrams > Page 3130
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Powertrain Control Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3133
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Testing and Inspection > Powertrain Control Module Response Test > Page 3134
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground.
- The white wires in the sensor connector are the power and ground circuits for the heater.
- Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor
connector.
3. Resistance should be between 4 and 7 ohms.
- If not replace the sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Downstream Oxygen Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
Fig 122 Oxygen Sensor Grommet Cover
WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen
sensor.
REMOVAL
1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122).
Fig 123 Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123).
Fig 124 Oxygen Sensor Removal & Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the
sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If
using original sensor, coat the threads
with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 3137
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Oxygen Sensor > Component
Information > Service and Repair > Downstream Oxygen Sensor Replacement > Page 3138
Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Fig 121 Upstream Heated Oxygen Sensor
The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121).
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when
servicing the oxygen sensor.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Technical Service Bulletins > BCM Auto Lamp DTC Diagnostics
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations
Body Control Module: Component Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Locations > Component Locations >
Page 3146
Body Control Module Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3149
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3150
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3151
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3152
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3153
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3154
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3155
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3156
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3157
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3158
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3159
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3160
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3161
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3162
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3163
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3164
Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3165
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3166
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3167
Body Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3168
Body Control Module: Electrical Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3169
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3170
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3171
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3172
Exterior Lighting (Park Lamps)
Information Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3173
Instrument Cluster
Interior Lighting
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3174
Power Door Locks W/Remote Keyless Entry (RKE)
Power Door Locks W/O Remote Keyless Entry (RKE)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3175
Radio (CCD) Without Infinity Sound
Radio (CCD) With Infinity Sound
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3176
Vehicle Communications
Vehicle Theft Security System (VTSS)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3177
Windshield Wiper (Front)
Windshield Wiper (Rear)
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3178
Body Control Module (Part 1 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3179
Body Control Module (Part 2 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3180
Body Control Module (Part 3 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3181
Body Control Module (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3182
Body Control Module (Part 5 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3183
Body Control Module (Part 6 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Diagrams > Diagram Information and
Instructions > Page 3184
Body Control Module (Part 7 Of 7)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician
Safety Information
Body Control Module: Technician Safety Information
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following approved procedures is very important to the safety of individuals performing
diagnostic tests.
DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and
can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED
or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive
wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Service Precautions > Technician
Safety Information > Page 3187
Body Control Module: Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will
severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with
rubbing alcohol.
Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the
test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear
view mirror or operate it yourself. Have an assistant available to operate the DRB.
Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes
or error messages may occur.
Servicing Sub-Assemblies
Some components of the body system are intended to be serviced in assembly only. Attempting to
remove or repair certain system sub-components may result in personal injury and/or improper
system operation. Only those components with approved repair and installation procedures in the
service manual should be serviced.
DRBIII Safety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious
or possibly fatal injury. Carefully read and understand the cautions and the specification limits.
^ Follow the vehicle manufacturer's service specifications at all times.
^ Do not use the DRB if it has been damaged.
^ Do not use the test leads if the insulation is damaged or if metal is exposed.
^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
^ Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
^ Do not exceed the limits shown in the table below:
FUNCTION/INPUT LIMIT
Volts 0 - 500 peak volts AC 0 - 500 volts DC
Ohms (resistance)* 0-1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated 0 - 10 kHz
Temperature -58 - 11000 F -50 - 600 C
* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered
circuit.
^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
^ Use caution when measuring voltage above 25v DC or 25v AC.
^ The circuit being tested must be protected by a 1OA fuse or circuit breaker.
^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure
circuits exceeding 10A.
^ When testing for the presence of voltage or current, make sure the meter is functioning correctly.
Take a reading of a known voltage or current before accepting a zero reading.
^ When measuring current, connect the meter in series with the load.
^ Disconnect the live test lead before disconnecting the common test lead.
^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid
measuring error form outside interference.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code
Body Control Module: Application and ID Body Code
Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager
Body Code = NS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Application and ID > Body Code >
Page 3190
Body Control Module: Application and ID Glossary of Terms
ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System
Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler
Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC
Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic
Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET
Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger
PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature
Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum
Fluorescent Display VTSS Vehicle Theft Security System
NOTE: The following terms are used interchangeably:
- Left Front (LF) Door & Driver (DR) Door
- Right Front (RF) Door and Passenger (PASS) Door
- "Gage" and "Gauge"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System
Body Control Module: Description and Operation Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3193
Body Control Module: Description and Operation Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3194
Body Control Module: Description and Operation Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3195
Body Control Module: Description and Operation Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3196
Body Control Module: Description and Operation
Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3197
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Compass Mini-Trip Computer (CMTC)
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Auto Headlamps
On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control
the exterior lamp operation by monitoring the mode selection switch located in the headlamp
control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal
from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light
levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Battery Protection: "Park & Headlamps"
This feature provides a battery protection scheme to avoid wearing down the battery if the
customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If
the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the
ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to
be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will
enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of
sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless
Entry (RKE) actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power on) will inhibit the battery protection routine from turning off the exterior lamps as described
above.
Exterior Headlamp Control
The headlamps and parklamps are illuminated via external relays which are controlled by the body
controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the
parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is
also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp
switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays.
The position of the hi-beam select switch will determine the mode of operation.
Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams
will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time.
Headlamp Time Delay
The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and
passengers security lighting when exiting the vehicle. This feature is only available on vehicles
equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by
sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and
parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp
delay. This 45 second window is new for the NS body. Once the headlamp delay has been
activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto
headlamp or the ignition switch changes states.
Identification of System
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3198
The vehicle systems that are part of the "body" system are:
- airbag system
- chimes
- compass/mini-trip
- courtesy lamps I panel dimming
- headlamp time delay
- illuminated entry
- radio (CCD)
- information center
- mechanical instrument cluster (MIC)
- power door locks
- remote keyless entry (RKE)
- vehicle communications
- vehicle theft security system (VTSS)
- wipers
Vehicles equipped with the highline body control module can be identified by the presence of the
vehicle theft security system (VTSS). Vehicles with the midline body control module may have a
compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or
illuminated entry. Vehicles with a base body control module will not have any of these features.
Introduction
Diagnostic procedures change every year. New diagnostic systems may be added; carryover
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO
BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These
tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover
all the necessary requirements to begin a logical diagnostic path for each repair. If there is a
trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you
to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are
used to direct you alphabetically to the specific systems.
NOTE: The following terms are used interchangeably:
Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door
Mechanical Instrument Cluster (MIC)
The body control module sends the angular position of the gauges, the status of all CCD indicator
lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus
when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped)
and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions;
all other MIC features work only when the ignition is in the "run" position. On transition of the
ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all
CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The
PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine
exceeds 450 rpm.
Power Door Lock System
When the body control module (BCM) receives an input for a lock request (door lock switch, RKE,
or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount
of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM
considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck,
the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates
in the same fashion as the lock signal. The door lock switches provide a variable amount of
resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond
to that command.
Other power door lock features:
Sliding Door Memory Lock
When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on
the lock relay as described above, and will turn it on again when all sliding doors are closed.
NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the
memory lock.
Door Lock Inhibit
When the key is in the ignition and in the off position, and any door except the rear liftgate is open,
all door lock switches are disabled. The unlock switches are still functional. This protects against
locking the vehicle with the keys still in the ignition.
Automatic Door Locks
This feature can be enabled or disabled by using either the DRBIII or customer programming
method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all
doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will
operate again once all doors are closed and the speed is above 15 MPH.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3199
RKE (Remote Keyless Entry) Interface
The body control module interfaces with the RKE receiver via a one-way serial bus interface. The
RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the
transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of
the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4
individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the
BCM will ground the interface wire thereby disabling the RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the on position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Radio System
There are three radio systems available this year that will be on the CCD bus. They are the RBR,
RBN and RAZ models. The main reason they are on the bus is because of the radio remote
controls in the steering wheel. They can control volume up/down, seek up, seek down and preset
station selections. These systems also communicate with the body control module and will set a
specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers
receive their signals from the quarter speakers. Depending on the manufacture some systems will
have a Front/Rear channel system and others will have a Left/Right channel system. If one of the
main quarter speaker audio circuits experiences a short, the other speakers on that channel will
also shut down until the circuit is repaired. The radio will also set a trouble code, which is
assessible with the DRB, indicating which channel is effected.
Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS)
This passive system is designed to protect against theft. The vehicle theft security system (VTSS)
is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for
unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park
and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after
closing them. The indicator lamp in the information center will flash for 15 seconds, showing that
arming is in progress. If no monitored systems are activated during this period, the system will arm.
If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain
steadily lit during the arming process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes.
Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it
means the alarm was activated. Check the vehicle for tampering.
Manual Override - The system will not arm if the doors are locked using the manual lock control (by
hand) or if the locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows:
1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with
the power lock switch. 4. Close the driver's door.
NOTE: After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may
be a problem with the system.
System initialization is accomplished by:
1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder
to unlock/disarm position.
Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all doors are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3200
been activated.
System Self-Test
NOTE: System self-test can be entered only with the DRB.
NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system
cannot be used in a vehicle that is not equipped with a vehicle theft security system.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
Shipping Mode
By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle.
The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse.
The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping
mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will
not operate until the IOD is reconnected or the ignition switch is turned to the run/start position.
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
System Coverage
These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth
Voyager vehicles equipped with either base, midline, or highline body control modules.
Airbag Trouble Code Descriptions
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of the trouble codes. It
is not necessary to perform all of the tests in the airbag section to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
"AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must
be performed. If more than one code exists, diagnostic priority should be given to the active
code(s).
Active diagnostic trouble codes for the airbag system are not permanent and will change the
moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes
are used as a diagnostic tool.
Active Codes
An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is
currently there every time the airbag control module checks that circuit/function. It is impossible to
erase an active code; active codes automatically erase by themselves when the reason for the
code has been corrected.
With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is
detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction
is present.
Stored Codes
An airbag trouble code becomes active and stored as soon as it is detected with the exception of
the Loss of Ignition Run Only code, which is an active code only.
A "stored" code indicates there was an active code present at some time. However, the code
currently may not be present as an active code, although another active code could be.
When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even
if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes
it was active, and the number of times the ignition has been cycled since the problem was last
detected.
The minimum time shown for any code will be one minute, even if the code was actually present for
less than one minute. Thus, the time shown for a code that was present for two minutes 13
seconds, for example, would be three minutes.
If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as
the malfunction exists. When and if the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3201
malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle
count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is
erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count
reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will
continue to be a stored code.
If a malfunction is not active while performing a diagnostic test procedure, the active code
diagnostic test will not locate the source of the problem. In this case, the stored code can indicate
an area to inspect.
If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire
harness and connectors. Recheck for codes periodically as you work through the system. This
procedure may uncover a malfunction that is difficult to locate.
Airbag Diagnostic Trouble Codes
The airbag control module may report any of the following diagnostic trouble codes.
For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer
- AECM Internal Diagnostic 2
- AECM Internal Diagnostic 1
- AECM Output Driver
- AECM Stored Energy
- Internal Diagnostic 3
- Incorrect AECM
For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open
- No CCD Communication
- Driver Squib Circuit Shorted
- Passenger Squib Circuit Open
- Driver Squib Term Shorted to Battery
- Passenger Squib Circuit Shorted
- Driver Squib Term Shorted to Ground
- Pass Squib Term Shorted to Battery
- Loss of Ignition Run Only
- Pass Squib Term Short to Ground
- Loss of Ignition Run/Start
- Warning Lamp Circuit Open
- Output Driver Not Tested
- Warning Lamp Circuit Shorted
Driver Squib Circuit Open
NAME OF CODE
Driver Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring open or high resistance in clockspring
- Driver side airbag module open
- Driver airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Driver Squib Circuit Shorted
NAME OF CODE
Driver Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring short
- Driver side airbag module short
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3202
- Driver airbag line 1 shorted to line 2
- Loose, or poor connector not completely connected
Driver Squib Term Shorted to Battery
NAME OF CODE
Driver Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to voltage
- Driver airbag line 2 short to voltage
- Faulty clockspring
- Faulty airbag control module
Driver Squib Term Shorted to Ground
NAME OF CODE
Driver Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to ground potential
- Driver airbag line 2 short to ground potential
- Faulty clockspring
- Faulty airbag control module
Loss of Ignition Run Only
NAME OF CODE
Loss of Ignition Run Only
NOTE: This code becomes active as soon as the condition is detected (this is not a stored code).
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Open ignition run circuit
- Open fuse
- Ignition run circuit short to ground
- Loose or poor connection at connector terminals
Loss of Ignition Run/Start
NAME OF CODE
Loss of Ignition Run/Start
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3203
- Open ignition run/start circuit
- Open fuse
- Ignition run/start circuit short to ground
- Loose or poor connection at connector terminals
Passenger Squib Circuit Open
NAME OF CODE
Passenger Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) open
- Passenger airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Passenger Squib Circuit Shorted
NAME OF CODE
Passenger Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) short
- Passenger airbag line 1 shorted to line 2
- Loose or poor connection at connector terminals
Pass Squib Term Shorted to Battery
NAME OF CODE
Pass Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to voltage
- Passenger airbag line 2 short to voltage
- Faulty airbag control module
Pass Squib Term Shorted to Ground
NAME OF CODE
Pass Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to ground potential
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3204
- Passenger airbag line 2 short to ground potential
- Faulty airbag control module
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NAME OF CODE
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or
during a lamp check.
SET CONDITION
With the voltage on, the airbag warning lamp driver circuit is other than expected.
POSSIBLE CAUSES
- Faulty warning lamp
- Open fused ignition switch output circuit to Information Center
- Airbag warning lamp driver circuit short to ground
- Airbag warning lamp driver circuit short to voltage
- Faulty information center printed circuit board
- Loose or poor connection at connector terminal
Output Driver Not Tested
NAME OF CODE
Output Driver Not Tested
WHEN MONITORED
At ignition on.
SET CONDITION
This code may set whenever another code is set due to any short to battery or short to ground
failure of the squib circuits. If all other squib codes have been repaired and this code appears
active by itself, the problem will be an internal failure of the airbag control module.
POSSIBLE CAUSES
- Short circuit to ground or to battery in either driver or passenger airbag lines
- Defective airbag control module
Trouble Code Testing Notes
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of trouble codes. It is
not necessary to perform all of the tests to diagnose an individual code.
The body control module will set a diagnostic trouble code if a monitored input is determined to be
malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the
trouble code condition is removed, the body control module will back out the diagnostic trouble
code if the trouble code condition remains cleared for twenty ignition cycles.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This
will direct you to the specific test(s) that must be performed.
ASB Message Not Received
NAME OF CODE
ASB Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from CAB every second. If this message is not received by the BCM
for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from CAB to BCM
Airbag Message Not Received
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3205
NAME OF CODE
Airbag Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from ACM every second. It this message is not received by the BCM
for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from ACM to BCM
Battery Power to Module Disconnected
NAME OF CODE
Battery Power to Module Disconnected
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
Battery power to the BCM is disconnected while the ignition is on.
THEORY OF OPERATION
The body control module checks battery input and determines if the battery is connected.
POSSIBLE CAUSES
- In shipping mode - IOD fuse missing
- Open wire
- Blown IOD fuse
EATX PRNDL Message Test Failed
NAME OF CODE
EATX PRNDL Message Test Failed
WHEN MONITORED
When engine is running.
SET CONDITION
The engine is running above 450 rpm and the body control module has not received a transmission
PRNDL message.
THEORY OF OPERATION
The body control module will monitor the CCD bus and look for the transmission PRNDL message
whenever the engine rpm is above 450.
POSSIBLE CAUSES
- Body Control module
- Transmission control module
- CCD bus failure
- Loss of power to transmission control module
EEPROM Checksum Failure
NAME OF CODE
EEPROM Checksum Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The sum of EEPROM constants does not equal the correct value.
THEORY OF OPERATION
By using a checksum, the BCM monitors the value of each programmable constant. The code is
set if any value is incorrect.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3206
- Body Control module
Front Wiper Park Switch CKT Open
NAME OF CODE
Front Wiper Park Switch Ckt Open
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Open wire
- Wiper motor
- Body Control module
Front Wiper Park Switch CKT-Shorted
NAME OF CODE
Front Wiper Park Switch Ckt-Shorted
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Shorted wire
- Wiper motor
- Body Control module
Fuel Level Sending Circuit Error
NAME OF CODE
Fuel Level Sending Circuit Error
WHEN MONITORED
With the ignition key on and battery voltage above 10 volts.
SET CONDITION
When the BCM senses an open or short on the fuel level sensor signal circuit.
THEORY OF OPERATION
The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on
fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be
set.
POSSIBLE CAUSES
- Open wire
- Shorted wire
- Fuel level sending unit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3207
- Body control module
Internal Module Test Failed
NAME OF CODE
Internal Module Test Failed
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The body control module performs an internal check and determines the body control module is not
functioning properly.
THEORY OF OPERATION
The body control module performs internal diagnostics on demand and determines if the body
control module microprocessor is functioning properly.
POSSIBLE CAUSES
- Body control module
Left Door Key CYL Arm SW Failure
NAME OF CODE
Left Door key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Key CYL Disarm SW Failure
NAME OF CODE
Left Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Lock Switch Failure
NAME OF CODE
Left Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3208
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Left Door Unlock Switch Failure
NAME OF CODE
Left Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Liftgate Key CYL Arm SW Failure
NAME OF CODE
Liftgate Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Key CYL Disarm SW Failure
NAME OF CODE
Liftgate Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3209
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Door Mux CKT Short to GND
NAME OF CODE
Liftgate Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (Liftgate Switch MUX)
- Body control module
LT Front Door Mux Circuit Short to GND
NAME OF CODE
LT Front Door MUX Circuit Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (LF Door Switch MUX)
- Body control module
No CCD Message From PCM
NAME OF CODE
No CCD Message From PCM
WHEN MONITORED
When the ignition is in the run or start position and battery voltage is above 10 volts.
SET CONDITION
The BCM looks for engine messages over the CCD bus and does not receive a message within a
2-second period.
THEORY OF OPERATION
The body control module will monitor the engine messages after the ignition has been turned on.
POSSIBLE CAUSES
- Body control module
- Powertrain control module
- CCD Bus failure
Rear Wiper Mux Circuit Error
NAME OF CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3210
Rear Wiper MUX Circuit Error
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts.
SET CONDITION
When the rear wiper MUX circuit senses a voltage above 5.0 volts.
THEORY OF OPERATION
The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The
CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level.
The voltage level will determine the wiper function to be performed. That level will be below 5.0
volts.
POSSIBLE CAUSES
- Circuit shorted to battery
- Open CCM ground circuit
Right Door Key CYL Arm SW Failure
NAME OF CODE
Right Door Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Key CYL Disarm SW Failure
NAME OF CODE
Right Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Lock Switch Failure
NAME OF CODE
Right Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3211
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
Right Door Unlock Switch Failure
NAME OF CODE
Right Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
RT Front Door Mux CKT Short to GND
NAME OF CODE
RT Front Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below .4 volts on the RF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (RF Door Switch MUX)
- Body control module
Horn Switch Failure
NAME OF CODE
Horn Switch Failure
WHEN MONITORED
Continuously with battery connected and IOD fuse installed.
SET CONDITION
The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering
wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more
than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The
horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to
cool down.
POSSIBLE CAUSES
- Shorted horn relay control circuit
- Defective horn switch
- Defective BCM
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3212
CCD Radio
NAME OF CODE
CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume
Down Switch (Stuck) Preset Switch (Stuck)
WHEN MONITORED
Anytime ignition is on and voltage is above 10.0 volts.
SET CONDITION
When a switch is held active for longer than 20 seconds.
THEORY OF OPERATION
The BCM monitors the control switches for an active condition and performs the required radio
function. When a switch is active for longer than 10 seconds, that switch function will be disabled
until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be
set.
POSSIBLE CAUSES
- Defective remote control switch
- Shorted radio control MUX circuit
Vehicle Communication
The body system consists of a combination of modules that communicate over the Chrysler
Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the
operation of vehicle components and circuits is relayed to the appropriate module(s). Each module
receives the same information about a component or circuit as the other modules do. This
significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus
plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
+ and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board
diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle
Communications section.
Any of the following bus failure messages may be displayed.
Short to Battery - Either or both of the bus wires are shorted to the battery potential.
Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential.
Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be
open.
Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together.
No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts.
Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their
normal 2.5 volts.
No Bus Bias - The bus system has lost connection with all modules that provide bias.
Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Description and Operation > Airbag
System > Page 3213
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias.
Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not
know why.
Wiper System
FRONT
The front wiper system provide the driver with normal wipe (low and high speeds), intermittent
wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a
resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on
position and the ignition is turned off, the wiper will continue to run until it reaches its park position.
Other front wiper system features:
Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay
of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay
time is doubled to provide a range time of from 1 second to 36 seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
REAR
The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics
Body Control Module: Component Tests and General Diagnostics
SELF DIAGNOSTIC TEST
To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the
TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to
the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in
the odometer windows (about five seconds) then release the
buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists
the code 999 (End Test) will momentarily appear.
INSTRUMENT CLUSTER DTC CHART
DTC .....................................................................................................................................................
.................................................... Description 110 ...............................................................................
.......................................................................................................... Memory Fault in cluster 111 .....
..............................................................................................................................................................
................... Calibration fault in cluster 905 .........................................................................................
................................................................................ No CCD bus messages from TCM 921 ..............
..............................................................................................................................................................
......... Odometer fault from BCM 940 ...................................................................................................
...................................................................... No CCD bus messages from PCM 999 ........................
..............................................................................................................................................................
.................... End of Codes
NOTE: For DTC testing see Condition Diagnostic Charts below.
CONDITIONS
Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Instrument Cluster Diagnosis
- Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Speedometer Diagnosis
- Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Tachometer Diagnosis
- Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Fuel Gauge Diagnosis
- Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Temperature Diagnosis
- Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Odometer Diagnosis
- Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis
- Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and
corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Calibration Table contains the proper calibration
points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If
any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III).
CLUSTER CALIBRATION TABLE
Speedometer .......................................................................................................................................
................................................. Calibration Point
1 ...........................................................................................................................................................
............................................... 0 mph (0 Km/h) 2 .................................................................................
..................................................................................................................... 20 mph (40 Km/h) 3 .......
..............................................................................................................................................................
................................. 55 mph (80 Km/h) 4 ...........................................................................................
.......................................................................................................... 75 mph(120 Km/h)
Tachometer .........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
............................................................... 0 rpm 2 ................................................................................
.................................................................................................................................... 1000 rpm 3 .....
..............................................................................................................................................................
................................................. 3000 rpm 4 ........................................................................................
............................................................................................................................ 6000 rpm
Fuel Gauge ..........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
......................................................... Empty(E) 2 .................................................................................
................................................................................................................................... 1/8 Filled 3 .......
..............................................................................................................................................................
............................................... 1/4 Filled 4 ...........................................................................................
............................................................................................................................ Full (F)
Temperature Gauge ............................................................................................................................
............................................... Calibration Point
1 ...........................................................................................................................................................
.......................................................... Cold (C) 2 .................................................................................
.............................................................................................................................. Low Normal 3 .......
..............................................................................................................................................................
......................................... High Normal 4 ............................................................................................
........................................................................................................................... Hot (H)
DIM TEST
When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays
will dim down. If the VF display brightness does
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics > Page 3216
no change, a problem exists in the cluster.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate
sequentially If a segment in the odometer does not illuminate normally, a problem exists in the
display.
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer window, each segment of the transmission range
indicator will illuminate sequentially. If a segment in the transmission range indicator does not
illuminate normally, a problem exists in the display board.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Component
Tests and General Diagnostics > Page 3217
Body Control Module: Scan Tool Testing and Procedures
Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing
trouble codes, and other DRB functions.
DRBIII Error Messages
Under normal operation, the DRB will display one of only two error messages:
- User-Requested WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the scantool
manufacturer for information and assistance. This is a sample of such an error message display:
ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD
boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRBIII Does Not Power Up (Blank Screen)
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a
bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts
is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A
Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3218
Body Control Module: Service and Repair
Body Control Module Location
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4.
Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting
bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control
Module downward to disengage guide studs on Junction Block from channels on BCM mounting
bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to
engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws
holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5.
Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom
of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker
reinforcement. 8. Connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Body Control Module > Component Information > Testing and Inspection > Page 3219
Body Control Module: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge (0-300 psi)
- Test Light
- Voltmeter
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Locations
Fig 1 Powertrain Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions
Powertrain Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3225
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3226
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3227
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3228
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3229
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3230
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3231
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3232
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3233
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3234
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3235
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3236
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3237
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3238
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3239
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3240
Powertrain Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3241
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3242
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3243
Powertrain Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3244
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3245
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Diagram Information and Instructions > Page 3246
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3247
Powertrain Control Module: Service Precautions
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3248
Powertrain Control Module: Description and Operation
Fig 1 Powertrain Control Module
POWERTRAIN CONTROL MODULE (PCM)
The PCM is a digital computer containing a microprocessor (Fig. 1). The PCM receives input
signals from various switches and sensors that are referred to as PCM Inputs. Based on these
inputs, the PCM adjusts various engine and vehicle operations through devices that are referred to
as PCM Outputs.
PCM Inputs: Air Conditioning Head Pressure
- Battery Voltage
- Brake Switch
- Camshaft Position Sensor
- Crankshaft Position Sensor
- Engine Coolant Temperature Sensor
- Heated Oxygen Sensors (Upstream and Downstream)
- Knock Sensor
- Manifold Absolute Pressure (MAP) Sensor
- SCI Receive
- Speed Control System Controls
- Throttle Position Sensor
- Transaxle Park/Neutral Position Switch (automatic transaxle)
- Transmission Control Module
- Vehicle Speed Sensor
PCM Outputs: Air Conditioning Clutch Relay
- Automatic Shutdown (ASD) Relay
- Data Link Connector
- Electric EGR Transducer
- Fuel Injectors
- Fuel Pump Relay
- Generator Field
- Idle Air Control Motor
- Ignition Coil
- Leak Detection Pump
- Malfunction Indicator (Check Engine) Lamp
- Proportional Purge Solenoid
- Radiator Fan Control Module
- Speed Control Solenoids
- Tachometer Output
- Torque Converter Clutch Solenoid (3 speed transmission)
- Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3249
Based on inputs it receives, the PCM adjusts fuel injector pulse width, idle speed, ignition spark
advance, ignition coil dwell and canister purge operation. The PCM regulates the cooling fan, air
conditioning and speed control systems. The PCM changes generator charge rate by adjusting the
generator field.
The PCM adjusts injector pulse width (air/fuel ratio) based on the following inputs: Battery voltage
- Engine coolant temperature
- Exhaust gas content (oxygen sensors)
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
The PCM adjusts ignition timing based on the following inputs: Barometric pressure
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
The PCM also adjusts engine idle speed through the idle air control motor based on the following
inputs: Air conditioning select switch head pressure
- Brake switch
- Engine coolant temperature
- Engine speed (crankshaft position sensor)
- Manifold absolute pressure
- Throttle position
- Transaxle gear selection (park/neutral switch)
- Vehicle distance (speed)
Automatic Shutdown (ASD) and Fuel Pump Relays The Automatic Shutdown (ASD) and fuel pump
relays are located in the Power Distribution Center (PDC).
The camshaft position sensor and crankshaft position sensor signals are sent to the PCM.
If the PCM does not receive both signals within approximately one second of engine cranking, it
deactivates the ASD relay and fuel pump relay. When these relays are deactivated, power is shut
off to the fuel injectors, ignition coil, oxygen sensor heating element and fuel pump.
PCM Regulated Output Voltages The PCM contains a voltage converter that changes battery
voltage to a regulated 8.0 volts to power the camshaft position sensor, crankshaft position sensor
and vehicle speed sensor. The PCM also provides a 5.0 volt supply for the manifold absolute
pressure sensor, throttle position sensor and engine coolant temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3250
Powertrain Control Module: Service and Repair
Fig 29 Power Distribution Center Retaining Screws
REMOVAL
1. Disconnect both cables from battery, negative cable first.
NOTE: On some models you will need to perform the LED reset procedure (LED's Flashing) after
disconnecting the battery. See: Heating and Air Conditioning/Testing and Inspection
2. Remove 2 screws holding Power Distribution Center (PDC) to bracket (Fig. 29).
Fig 30 Battery Heat Shield
3. Remove heat shield from battery (Fig 30).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3251
Fig 31 Battery Clamp
4. Remove nut and clamp holding battery to battery tray (Fig. 31). 5. Remove battery from vehicle.
Fig 32 PDC Rear Bracket
6. Rotate PDC toward center of vehicle to remove from rear bracket (Fig. 32). 7. Pull PDC rearward
to remove from front bracket. Lay PDC aside to allow access to Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3252
Fig 33 PCM 40 Way Connectors
8. Squeeze tabs on 40-way connector. Pull connector rearward to remove from PCM (Fig. 33).
Remove both way connectors.
Fig 34 PCM Removal/Installation
9. Remove 3 screws holding PCM to fender (Fig. 34).
10. Remove PCM from vehicle.
INSTALLATION
1. Connect 2 40-Way electrical connectors to PCM (Fig. 33). 2. Install PCM. Tighten mounting
screws. 3. Install PDC bracket. 4. Install battery.
NOTE: Use a DRB or equivalent scan tool to reprogram the new PCM with the vehicles original
identification number (VIN) and mileage. If this is not done a diagnostic trouble code (DTC) may be
set.
IMPORTANT NOTE: If the Powertrain Control Module has been changed and the correct VIN and
mileage have not been programmed, a DTC will be set in the ABS and Air bag modules. In
addition, if the vehicle is equipped with a Smart Key Immobilizer Module (SKIM), Secret Key data
must be updated to enable starting.
For ABS and Air Bag systems:
ACTION:
1. Enter correct VIN and Mileage in PCM. 2. Erase codes in ABS and Air Bag modules.
For SKIM theft alarm:
ACTION:
1. Connect the DRB to the data link connector. 2. Go to Engine, Misc. and place the SKIM in
secured access mode, by using the appropriate PIN code for this vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Powertrain Control Module <--> [Engine Control Module] > Component Information >
Diagrams > Page 3253
3. Select Update the Secret Key data, data will be transferred from the SKIM to the PCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3259
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3260
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3261
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3262
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3263
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3264
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3265
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3266
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3267
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3268
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3269
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3270
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3271
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3272
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3273
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3274
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3275
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3276
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Diagram Information and Instructions > Page 3277
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Diagrams > Page 3278
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Relays and Modules Computers and Control Systems > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] >
Component Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3281
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Testing and
Inspection/Diagnostic Trouble Code Tests and Associated Procedures/Manufacturer Code
Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST CHART (Checking for Trouble
Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Battery Temperature Sensor > Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Electrical
Specifications > Page 3290
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Specifications > Page 3291
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3294
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3295
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3296
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3297
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3298
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3299
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3300
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3301
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3302
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3303
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3304
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3305
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3306
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3307
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3308
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3309
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3310
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3311
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3312
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Diagram Information
and Instructions > Page 3313
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3314
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3315
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3316
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3317
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Camshaft Position Sensor > Component Information > Diagrams > Page 3318
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications
Coolant Temperature Sensor/Switch (For Computer): Specifications
Coolant Sensor ....................................................................................................................................
.......................................................... 7 Nm (62 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 3322
Engine Coolant Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 3323
Engine Coolant Temperature Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 3324
Coolant Temperature Sensor/Switch (For Computer): Description and Operation
PURPOSE
The Powertrain Control Module (PCM) uses ECT sensor input to calculate injector pulse width, idle
speed, and ignition spark advance.
OPERATION
The sensor element extends into the coolant passage, where it maintains constant contact with the
engine coolant.
The ECT sensor is a Negative Temperature Coefficient (NTC) thermistor. (As temperature
increases, sensor resistance decreases.)
The sensor is a variable resistance (thermistor) with a range of -40°F to 265°F. As coolant
temperature varies, the sensors resistance changes, resulting in a different input voltage to the
PCM.
The PCM contains different spark advance schedules for cold and warm engine operation. The
schedules reduce engine emission and improve driveability.
When the engine is cold, the PCM will demand slightly richer air-fuel mixtures and higher idle
speeds until normal operating temperatures are reached.
The ECT sensor input is also used for cooling fan control.
The PCM supplies a reference voltage of approximately 5 volts to the sensor, see THEORY below.
As sensor resistance changes, the voltage drop across the sensor changes.
The PCM translates the voltage drop across the sensor into engine coolant temperature.
THEORY
As the engine warms up the ECT sensor becomes less accurate. To keep sensor readings
accurate at all times, the 5 PCM routes the reference voltage through either a 10,000 ohm resistor
(cold operation), or a 909 ohm resistor (warm operation).
The resistance circuits are inside the PCM.
For accurate readings at cold temperatures (below 125° F.), the 5 volt reference is fed through the
10,000 ohm resistor.
When the engine reaches approximately 125° F the PCM switches the 5 volt reference through the
909 ohm resistor circuit, making the ECT sensor more accurate at higher temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 3325
Coolant Temperature Sensor/Switch (For Computer): Testing and Inspection
Fig 95 Engine Coolant Temperature Sensor
1. With the key OFF, disconnect wire harness connector from coolant temperature sensor (Fig. 95).
Fig 96 Engine Coolant Temperature Sensor Connector
2. Connect a high input impedance (digital) volt-ohmmeter to terminals A and B (Fig. 96). The
ohmmeter should read as follows:
- Normal operating temperature around 200°F ohmmeter should read approximately 700 to 1,000
ohms.
- Room temperature around 70°F ohmmeter should read approximately 7,000 to 13,000 ohms.
3. Test the resistance of the wire harness between the PCM connector terminal 26 and the sensor
harness connector. Also check for continuity
between PCM connector terminal 43 and the sensor harness connector. If the resistance is greater than 1 ohm, repair the wire harness as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Coolant Temperature Sensor/Switch (For Computer) > Component Information >
Specifications > Page 3326
Coolant Temperature Sensor/Switch (For Computer): Service and Repair
Fig 129 Engine Coolant Temperature Sensor
WARNING: Hot, pressurized coolant can cause injury by scalding. cooling system must be partially
drained before removing the coolant temperature sensor. Refer to Cooling System.
NOTE: The Engine Coolant Temperature (ECT) sensor is located below the ignition coil.
REMOVAL
1. Drain cooling system until coolant level is below sensor. Refer to Cooling System. 2. Disconnect
electrical connector from engine coolant temperature sensor. 3. Remove sensor from engine.
INSTALLATION
1. Tighten the sensor to 7 Nm (60 in lb) torque. 2. Connect electrical connector to sensor. 3. Fill
cooling system. Refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Specifications > Page 3330
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3333
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3334
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3335
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3336
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3337
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3338
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3339
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3340
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3341
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3342
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3343
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3344
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3345
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3346
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3347
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3348
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3349
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3350
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3351
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Diagram
Information and Instructions > Page 3352
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3353
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3354
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3355
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Crankshaft Position Sensor > Component Information > Diagrams > Page 3356
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Fuel Level Sensor > Component Information > Diagrams
Fuel Tank Sending Unit Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3363
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3364
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3365
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Knock Sensor > Component Information > Locations > Page 3366
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications
Manifold Pressure/Vacuum Sensor: Specifications
MAP Sensor ........................................................................................................................................
.......................................................... 4 Nm (35 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
3370
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
3371
Map Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
3372
Manifold Pressure/Vacuum Sensor: Description and Operation
PURPOSE
At start-up, the Powertrain Control Module (PCM) uses sensor to read barometric (atmospheric),
pressure, for reference, to calculate air/fuel mixture.
During operation the Powertrain Control Module (PCM) monitors sensor input to adjust spark
advance and air/fuel mixture.
OPERATION
PCM supplies 5 volt sensor reference voltage.
Sensor, connected to manifold vacuum at throttle body, converts intake manifold pressure into
voltage.
THEORY
Sensor resistance and manifold absolute pressure are inversely proportional (as manifold absolute
pressure increases, (low vacuum), sensor resistance decreases and vice versa).
OUTPUT VOLTAGES
Sensor output voltage range is 0.5 to 4.5 volts. Output voltages between 0.5 and 1.5 volts indicate a high vacuum situation, such as idle or
deceleration.
- Output voltages between 1.5 and 3.0 volts indicate a medium level of vacuum such as a cruise or
slight acceleration condition.
- Output voltages between 3.0 and 4.5 volts indicate a low vacuum situation such as hard
acceleration or a mechanical failure.
- Any reading of 0 volts or over 5 volts indicates a problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
3373
Manifold Pressure/Vacuum Sensor: Testing and Inspection
Fig 92 Map Sensor Connector
NOTE: To perform a complete test of the MAP sensor and its circuitry, use a scan tool and
appropriate Diagnostics Procedures. To test the MAP sensor only, refer to the following:
CAUTION: When testing the MAP sensor, be sure that the harness wires are not damaged by the
test meter probes.
1. Test the MAP sensor output voltage at the MAP sensor connector between terminals 2 and 3
(Fig. 92). With the ignition switch ON and the engine
not running, output voltage should be 4 to 5 volts. The voltage should drop to 1.5 to 2.1 volts with a
hot, neutral idle speed condition. If OK, go to next step.
- If not OK, go to step 3.
2. Test PCM terminal 36 for the same voltage described in the previous step to verify wire harness
condition.
- Repair as required.
3. Test the MAP sensor ground circuit at sensor connector terminal 1 and PCM terminal 43.
- If OK, go to next step.
- If not OK, repair as required.
4. Test MAP sensor supply voltage between sensor connector terminals 2 and 1 with the key ON.
The voltage should be approximately 5 volts (4.5
to 5.5V). Five volts (4.5 to 5.5V) should also be at terminal 61 of the PCM. If OK, replace MAP sensor.
- If not OK, repair or replace the wire harness as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Manifold Pressure/Vacuum Sensor > Component Information > Specifications > Page
3374
Manifold Pressure/Vacuum Sensor: Service and Repair
Fig 9 MAP Sensor
REMOVAL
1. Disconnect electrical connector from MAP sensor. 2. Remove 2 screws holding sensor to intake
manifold (Fig. 9). 3. Remove sensor from manifold.
INSTALLATION
- Reverse the above procedure for installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications
Oxygen Sensor: Electrical Specifications
Air/Fuel Oxygen Exhaust
Ratio Sensor Voltage Gas Content
12.0:1 1.0 Volts [1] 5.0% CO [2]
13.0:1 0.85 Volts 3.8% CO [2]
14.0:1 0.65 Volts 1.3% CO [2]
14.7:1 0.45 Volts [5] 0.1% CO [2]
15.0:1 0.35 Volts 2.0% O2 [3]
16.0:1 0.25 Volts 3.0% O2 [3]
17.0:1 0.10 Volts [4] 4.0% O2 [3]
Remarks
[1] Full rich condition. [2] CO: Carbon monoxide, is a sign of incomplete ignition, (not enough
oxygen to burn all the hydrocarbons in cylinder). [3] O2: Oxygen left over after all hydrocarbons
have been burned. [4] Full lean condition. [5] Stoichiometric point: Output voltages below 0.45 volts
indicate a lean condition, and output voltages over 0.45 volts indicate a rich
condition.
NOTE: Both lean and rich conditions are usually accompanied by high Hydrocarbon (HC) readings.
Due to not enough fuel, (lean misses), or too much fuel, (not enough oxygen to burn all
hydrocarbons).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Specifications > Electrical Specifications >
Page 3379
Oxygen Sensor: Mechanical Specifications
Upstream 02S ......................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Downstream 02S .................................................................................................................................
......................................................... 27 Nm (20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations
Oxygen Sensor: Component Locations
Oxygen Sensor Bank Locations
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Oxygen Sensor
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Locations > Component Locations > Page
3382
Oxygen Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor
Connector
Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Upstream Oxygen Sensor
Connector > Page 3385
Downstream Heated Oxygen Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3386
Oxygen Sensor: Application and ID
The first oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/1.
The second oxygen sensor in cylinder bank #1 is numbered O2 Sensor 1/2.
A third oxygen sensor in cylinder bank #1 would be numbered O2 Sensor 1/3.
The first oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/1.
The second oxygen sensor in cylinder bank #2 is numbered O2 Sensor 2/2.
- Cylinder bank number one is the bank that contains number one cylinder. See: Ignition
System/Firing Order/Specifications - If a V-6 or V-8 vehicle only uses one downstream Heated
Oxygen Sensor (HO2S) it is numbered O2 Sensor 1/2, even if it uses two upstream
HO2S.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Diagrams > Page 3387
Oxygen Sensor: Description and Operation
O2 Sensor Cutaway View (Typical)
SENSOR PURPOSE
Powertrain Control Module (PCM) uses input to determine whether to enrich or lean air/fuel
mixture, during closed loop operation.
SENSOR OPERATION
The oxygen sensor generates a varying voltage signal dependent upon exhaust gas oxygen
content at that point in the exhaust.
- Oxygen sensor voltage signal is produced through a galvanic reaction within the sensors.
Using the oxygen sensor voltage signal as an air/fuel ratio indicator the PCM can tell how well the
system is responding to its output signals.
- Changes in the sensor signal occur because the air/fuel ratio is constantly changing.
- When oxygen content is low (rich mixture), the voltage signal will be approximately 1 volt.
- When oxygen content is high (lean mixture), the voltage signal will be low, approximately 0.1 volt.
Closed Loop During CLOSED LOOP operation, the PCM monitors the signals it receives from the
oxygen sensor, and other sensors, and uses these signals to adjust the injector pulse width
according to the current driving condition.
Open Loop During OPEN LOOP operation, the PCM ignores the oxygen sensor's signals, and
other sensor's signals, and adjusts injector pulse widths according to preprogrammed
specifications in the PCM.
HEATER PURPOSE
Vehicle enters CLOSED LOOP faster, (because sensor reaches operating temperature sooner).
Allows CLOSED LOOP operation during extended idle, (because heater maintains correct
operating temperature).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control
Module Response Test
Oxygen Sensor: Testing and Inspection Powertrain Control Module Response Test
Oxygen Sensor And Connector
NOTE: This test should be performed only after the Oxygen Sensor (O2S) has passed the
functional test and heating element test. NOTE: A four gas analyzer is needed to perform this test.
NOTE: When performing this test it is important that no part of your body contact the vehicle body,
as test results will be inaccurate. CAUTION: NEVER apply voltage directly to any computer sensor
wire. PRECONDITIONING AND SET UP
1. Run the engine at 2,500 rpm for 3 minutes with the transmission in PARK (A/T) or NEUTRAL
(M/T), (to ensure vehicle and oxygen sensor are
at operating temperature and vehicle is in closed loop).
2. Turn engine OFF, disconnect the oxygen sensor connector. Connect a jumper lead to the O2S
signal wire. 3. Start the engine and run at 2,500 rpm for 1 minute, with the transmission in PARK
(A/T), or NEUTRAL (M/T). 4. Let idle.
LEAN MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO ENRICH MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
negative, hold for 10 to 20 seconds.
- The CO and HC readings should increase, as the PCM opens the injectors for longer periods
(longer pulse width), to enrich the mixture.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
RICH MIXTURE SIMULATION (PCM SHOULD ATTEMPT TO LEAN OUT MIXTURE)
1. Touch one hand to the jumper wire from the O2S signal wire and the other hand to battery
positive, hold for 10 to 20 seconds.
- The O2 readings should begin to increase, and the CO reading should decrease.
2. If the readings do not change as described, further testing of the oxygen sensor circuit and/or
engine control system will be necessary. SEE
DIAGNOSIS BY SYMPTOM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control
Module Response Test > Page 3390
Oxygen Sensor: Testing and Inspection Sensor Functional Test
Oxygen Sensor And Connector
CAUTION: Use a high impedance [1] Digital Volt Ohm Meter (DVOM) ONLY, when testing
components on computerized vehicles.
1. Make sure the vehicle is at normal operating temperature. Run the engine at 2,500 rpm for 3
minutes with the transmission in PARK (A/T) or
NEUTRAL (M/T).
CAUTION: To avoid damaging sensor, voltmeter must be set in Volts mode only, (not ohms).
2. With engine OFF, connect the negative lead of the DVOM to engine ground. Set the DVOM to
read DC VOLTS. Disconnect the oxygen sensor (
O2S) electrical connector and connect the positive lead of the DVOM to the oxygen sensor signal
wire.
3. Start engine. Create a lean condition for 10 seconds. Voltage should decrease to 0.2 volt or less
and remain there. 4. Create a rich condition for 10 seconds. Voltage should increase to 0.8 volt or
more and remain there. 5. If sensor fails to vary according to the test steps above, the sensor is
defective. 6. Connect sensor and clear codes.
Remarks:
[1] Minimum 10 Meg (10,000,000) ohm input impedance.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Testing and Inspection > Powertrain Control
Module Response Test > Page 3391
Oxygen Sensor: Testing and Inspection Sensor Heating Element Test
1. Disconnect the Heated Oxygen Sensor (O2S), electrical connector from the wiring harness. 2.
Set DVOM to read OHMS. Connect the ohmmeter between the heater feed and heater ground.
- The white wires in the sensor connector are the power and ground circuits for the heater.
- Connect the ohmmeter test leads to terminals of the white wires in the heated oxygen sensor
connector.
3. Resistance should be between 4 and 7 ohms.
- If not replace the sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen
Sensor Replacement
Oxygen Sensor: Service and Repair Downstream Oxygen Sensor Replacement
Fig 122 Oxygen Sensor Grommet Cover
WARNING: The exhaust manifold may be extremely hot -- use care when servicing the oxygen
sensor.
REMOVAL
1. Raise and support vehicle. 2. Remove grommet cover to expose connector (Fig. 122).
Fig 123 Oxygen Sensor Connector Locking Tab
3. Push locking tab back and unplug oxygen sensor electrical connector (Fig. 123).
Fig 124 Oxygen Sensor Removal & Installation
4. Use a socket such as Snap-On YA8875 or equivalent to remove sensor (Fig. 124). 5. When the
sensor is removed, the exhaust manifold threads must be cleaned with an 18 mm X 1.5 +6E tap. If
using original sensor, coat the threads
with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen
Sensor Replacement > Page 3394
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Oxygen Sensor > Component Information > Service and Repair > Downstream Oxygen
Sensor Replacement > Page 3395
Oxygen Sensor: Service and Repair Upstream Oxygen Sensor Replacement
Fig 121 Upstream Heated Oxygen Sensor
The upstream oxygen sensor is installed in the exhaust manifold (Fig. 121).
CAUTION: Do not pull on the oxygen sensor wire when unplugging the electrical connector.
WARNING: The exhaust manifold and catalytic converter may be extremely hot. Use care when
servicing the oxygen sensor.
REMOVAL
1. Raise and support vehicle. 2. Unplug oxygen sensor electrical connector. 3. Use a socket such
as Snap-On YA8875 or equivalent to remove sensor. 4. When the sensor is removed, the exhaust
manifold threads must be cleaned with an 18 mm X 1.5 + 6E tap. If using original sensor, coat the
threads with Loctite 771-64 anti-seize compound or equivalent.
INSTALLATION
1. Reverse removal procedure to install a new sensor.
- New sensors are packaged with compound on the threads and no additional compound is
required.
- The sensor must be tightened to 27 Nm (20 ft lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Component Locations
> Page 3400
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3401
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3402
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3403
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3404
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Throttle Position Sensor > Component Information > Locations > Page 3405
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3414
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3415
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3416
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 3422
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 3423
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 3428
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 3429
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 3430
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 3436
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service
Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission
Range Sensor - Production Change > Page 3437
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly > Page 3440
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations >
Transmission Solenoid and Pressure Switch Assembly > Page 3441
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3442
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3443
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3444
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page
3445
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Locations
Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3451
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3452
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3453
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3454
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3455
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3456
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3457
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3458
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3459
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3460
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3461
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3462
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3463
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3464
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3465
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3466
Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3467
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Diagrams > Diagram Information and
Instructions > Page 3468
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit
Operation
Vehicle Speed Sensor: Description and Operation Circuit Operation
CIRCUIT OPERATION
If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM)
transmits the vehicle speed signal to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit
Operation > Page 3471
Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM
NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor.
CIRCUIT OPERATION
The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that
information to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Circuit
Operation > Page 3472
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation
Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical
OPERATION
The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM.
The speed and distance signals, along with a closed throttle signal from the TPS, determine if a
closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired
MAP value.
- Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine
speed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Sensors and Switches Computers and Control Systems > Vehicle Speed Sensor > Component Information > Description and Operation > Page
3473
Vehicle Speed Sensor: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain
Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also
refer to the DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Component Locations > Page 3478
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3479
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3480
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3481
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3482
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Throttle Position Sensor >
Component Information > Locations > Page 3483
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Torque Reduction Signal >
Component Information > Description and Operation
Torque Reduction Signal: Description and Operation
OPERATION
The torque reduction data link line is connected between the Transmission Control Module (TCM)
and the Powertrain Control Module (PCM). It is used as a communication link for the TCM to
instruct the PCM to back down the engine torque output before the vehicle shifts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3495
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3496
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 3497
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
3503
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
3504
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3509
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3510
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
3511
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3517
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 3518
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
3521
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
3522
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3523
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3524
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3525
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 3526
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Locations
Vehicle Speed Sensor: Locations
Fig. 26
Note: The transaxle output speed sensor supplies the vehicle speed and distance inputs to the
PCM. The output speed sensor is located on the side of
the transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions
Vehicle Speed Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3532
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3533
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3534
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3535
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3536
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3537
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3538
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3539
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3540
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3541
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3542
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3543
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3544
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3545
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3546
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3547
Vehicle Speed Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3548
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Diagrams > Diagram Information and Instructions > Page 3549
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Circuit Operation
Vehicle Speed Sensor: Description and Operation Circuit Operation
CIRCUIT OPERATION
If the vehicle is equipped with an automatic transaxle, the Transmission Control Module (TCM)
transmits the vehicle speed signal to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Circuit Operation > Page 3552
Vehicle Speed Sensor: Description and Operation Vehicle Speed Output From the TCM
NOTE: The following information applies to vehicles not equipped with a vehicle speed sensor.
CIRCUIT OPERATION
The Transmission Control Module (TCM) is used to calculate the vehicle speed and provide that
information to the Powertrain Control Module (PCM).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Circuit Operation > Page 3553
Vehicle Speed Sensor: Description and Operation Vehicle Speed Sensor Operation
Fig 25 Park/Neutral Switch -- 4 Speed Electronic Automatic Transaxle -- Typical
OPERATION
The transaxle output speed sensor supplies the vehicle speed and distance inputs to the PCM.
The speed and distance signals, along with a closed throttle signal from the TPS, determine if a
closed throttle deceleration or normal idle condition (vehicle stopped) exists. Under deceleration conditions, the PCM adjusts the idle air control motor to maintain a desired
MAP value.
- Under idle conditions, the PCM adjusts the idle air control motor to maintain a desired engine
speed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Vehicle Speed Sensor >
Component Information > Description and Operation > Page 3554
Vehicle Speed Sensor: Testing and Inspection
For diagnosis and testing of the Vehicle Speed Sensor (VSS), refer to the Powertrain
Management/Computer and Control Systems/appropriate Powertrain Diagnostic Procedures. Also
refer to the DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Computers and Control Systems > Voltage Signal > Component
Information > Description and Operation
Voltage Signal: Description and Operation
PURPOSE
Supplies Powertrain Control Module (PCM), with current charging system voltage.
OPERATION
If the PCM senses low battery voltage:
- PCM increases injector pulse width to compensate for low voltage.
- PCM increases generator field voltage.
If the PCM senses high battery voltage:
- PCM decreases injector pulse width to compensate for high voltage.
- PCM decreases generator field voltage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter
Technical Service Bulletin # J25 Date: 091030
Recall - Replace Mopar(R) Value Line Catalytic Converter
October 2009
Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters
Models
1997 - 1999 (AN) Dodge Dakota
1998 - 1999 (BE) Dodge Ram Truck
1995 - 1999 (BR) Dodge Ram Truck
1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon
1996 - 1997 (LH) Chrysler LHS and Concorde
1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country
1998 (PL) Plymouth Neon
2003 (PT) Chrysler PT Cruiser
1998 - 1999 (TJ) Jeep(R) Wrangler
2001 (WJ) Jeep(R) Grand Cherokee
1994 (XJ) Jeep(R) Cherokee
1994 - 1995 (YJ) Jeep(R) Wrangler
1993 - 1998 (ZJ) Jeep(R) Grand Cherokee
NOTE:
This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter
installed.
IMPORTANT:
Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this
recall service on these vehicles before retail delivery. Involved vehicles can be determined by using
the VIP inquiry process.
Subject
During a prior service appointment, a Mopar Value Line catalytic converter was installed on about
47 of the above vehicles. These catalytic converters may fail an emissions inspection test.
Repair
The catalytic converter must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 3567
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to
record recall service completions and provide dealer payments.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 3568
Use the labor operation number and time allowances shown.
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Dealer Notification
To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab,
then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A
generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also
use the VIN list to follow up with all owners to schedule appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Customer Services Field Operations Chrysler Group LLC
Service Procedure
WARNING:
IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE
TORCH FLAME NEAR THE FUEL LINES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 3569
1. Raise and support the vehicle on an appropriate hoist.
2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration.
3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection.
4. Remove the exhaust clamp from the catalytic converter muffler connection.
5. Disconnect the oxygen sensor wiring.
6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal
becomes cherry red.
7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from
the exhaust pipe and the muffler.
8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter.
9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection.
10. Install the catalytic converter onto the exhaust pipe.
11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the
alignment slot.
12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp
nuts to 45 ft. lbs. (61 N.m).
13. Connect the oxygen sensor wiring.
14. Lower the vehicle from the hoist.
15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels.
16. Continue with Section B. Install the Authorized Modifications Label.
B. Install the Authorized Modifications Label:
Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the
Authorized Modifications Label. Then attach the label near the VECI label.
C. Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement
Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053)
and supply it to vehicle owners residing in the state of California for proof that this recall has been
performed when they renew the vehicle registration.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Recalls for Catalytic Converter: > J25 > Oct > 09 > Recall - Replace Mopar(R)
Value Line Catalytic Converter > Page 3570
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter
Technical Service Bulletin # J25 Date: 091030
Recall - Replace Mopar(R) Value Line Catalytic Converter
October 2009
Dealer Service Instructions for: Emissions Recall J25 Mopar Value Line Catalytic Converters
Models
1997 - 1999 (AN) Dodge Dakota
1998 - 1999 (BE) Dodge Ram Truck
1995 - 1999 (BR) Dodge Ram Truck
1995 - 1997 (FJ) Chrysler Sebring and Eagle Talon
1996 - 1997 (LH) Chrysler LHS and Concorde
1996 - 1998 (NS) Dodge Grand Caravan and Chrysler Town & Country
1998 (PL) Plymouth Neon
2003 (PT) Chrysler PT Cruiser
1998 - 1999 (TJ) Jeep(R) Wrangler
2001 (WJ) Jeep(R) Grand Cherokee
1994 (XJ) Jeep(R) Cherokee
1994 - 1995 (YJ) Jeep(R) Wrangler
1993 - 1998 (ZJ) Jeep(R) Grand Cherokee
NOTE:
This recall applies only to the above vehicles that had a Mopar Value Line catalytic converter
installed.
IMPORTANT:
Some of the involved vehicles may be in Dealer vehicle inventory. Dealers should complete this
recall service on these vehicles before retail delivery. Involved vehicles can be determined by using
the VIP inquiry process.
Subject
During a prior service appointment, a Mopar Value Line catalytic converter was installed on about
47 of the above vehicles. These catalytic converters may fail an emissions inspection test.
Repair
The catalytic converter must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 3576
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims submitted will be used by Chrysler Group LLC to
record recall service completions and provide dealer payments.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 3577
Use the labor operation number and time allowances shown.
Add the cost of the recall parts package plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Dealer Notification
To view this notification on DealerCONNECT, select "Global Recall System" on the Service tab,
then click on the description of this notification.
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule appointments for this service with their dealers. A
generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Vehicle Lists, Global Recall System, VIP and Dealer Follow Up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery. Dealers should also
use the VIN list to follow up with all owners to schedule appointments for this repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Customer Services Field Operations Chrysler Group LLC
Service Procedure
WARNING:
IF TORCHES ARE USED WHEN WORKING ON THE EXHAUST SYSTEM, DO NOT ALLOW THE
TORCH FLAME NEAR THE FUEL LINES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 3578
1. Raise and support the vehicle on an appropriate hoist.
2. Saturate the bolts and nuts with penetrating lubricant. Allow 5 minutes for penetration.
3. Remove the exhaust clamp from the exhaust pipe-to-catalytic converter connection.
4. Remove the exhaust clamp from the catalytic converter muffler connection.
5. Disconnect the oxygen sensor wiring.
6. Heat the exhaust pipe, catalytic converter and muffler connections with a torch until the metal
becomes cherry red.
7.3While the metal is still cherry red, twist the catalytic converter back and forth to separate it from
the exhaust pipe and the muffler.
8. If necessary, transfer the oxygen sensor(s) to the new catalytic converter.
9. Position the exhaust clamp over the exhaust pipe-to-catalytic converter connection.
10. Install the catalytic converter onto the exhaust pipe.
11. Install the muffler onto the catalytic converter until the alignment tab is inserted into the
alignment slot.
12. Install the exhaust clamp at the muffler and catalytic converter connection. Tighten the clamp
nuts to 45 ft. lbs. (61 N.m).
13. Connect the oxygen sensor wiring.
14. Lower the vehicle from the hoist.
15. Start the engine, inspect for exhaust leaks and exhaust system contact with the body panels.
16. Continue with Section B. Install the Authorized Modifications Label.
B. Install the Authorized Modifications Label:
Type or print (with a ballpoint pen) the necessary information shown in Figure 1 onto the
Authorized Modifications Label. Then attach the label near the VECI label.
C. Complete Proof of Correction Form for California Residents:
This recall is subject to the State of California Registration Renewal/Emissions Recall Enforcement
Program. Complete a Vehicle Emission Recall Proof of Correction Form (Form No. 81-016-1053)
and supply it to vehicle owners residing in the state of California for proof that this recall has been
performed when they renew the vehicle registration.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Catalytic Converter: > J25 > Oct > 09 > Recall
- Replace Mopar(R) Value Line Catalytic Converter > Page 3579
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 3580
Catalytic Converter: Service Precautions
NOTE: There is no regularly scheduled maintenance on the catalytic converter. If damaged, the
converter must be replaced.
CAUTION: Due to exterior physical similarities of some catalytic converters with pipe assemblies,
extreme care should be taken with replacement parts. There are internal converter differences
required in some parts of the country.
REACTION
The combustion reaction caused by the catalyst releases additional heat in the exhaust system.
Causing temperature increases in the area of the reactor under severe operating conditions. Such
conditions can exist when the engine misfires or otherwise does not operate at peak efficiency. Do
not remove spark plug wires from plugs or by any other means short out cylinders of the exhaust
system if equipped with a catalytic converter. Failure of the catalytic converter can occur due to
temperature increases caused by unburned fuel passing through the converter.
CATALYSTS
The use of the catalysts also involves some non-automotive problems. Unleaded gasoline must be
used to avoid poisoning the catalyst core. Do not allow engine to operate at fast idle for extended
periods (over 5 minutes). This condition may result in excessive exhaust system and floor pan
temperatures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Technical Service Bulletins > Page 3581
Catalytic Converter: Description and Operation
Three Way Catalyst (TWC)
PURPOSE
Reduces emission of the three major pollutants, (Carbon Monoxide (CO), Hydrocarbon (HC) and
Oxides of Nitrogen (NOx)), by up to 90%.
OPERATION
Oxidation Reaction
As exhaust gasses pass through converter, the platinum in the converter triggers an oxidation
(burning) reaction. During this process the HC and CO combine with oxygen, forming water vapor
(H2O) and Carbon Dioxide (CO2).
This process no effect on NOx emissions.
Reduction Reaction
The Rhodium in the converter converts the NOx into nitrogen and oxygen, in a "reduction" (removal
of oxygen), reaction.
OPERATING ENVIRONMENT
A complete catalytic reaction requires that the air/fuel mixture remains near 14.7:1. This can only
be achieved in a properly functioning feedback system with oxygen sensor.
The ideal converter operating temperature, for maximum emission reduction and long service life
is, 400°C - 800°C (750°F - 1500°F).
Engine malfunctions, (for example misfires), can cause temperatures in the converter to excede
1400°C (2500°F), which can melt substrate material.
CONSTRUCTION
Converter consists of: metal housing, ceramic grid substrate, and catalytic coating, (approximately
2 grams of platinum and rhodium).
CAUTION: Never use leaded fuel, as lead compounds tend to coat pores and active material,
reducing or eliminating catalyst activity.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Catalytic Converter: Initial Inspection and Diagnostic Overview
VISUAL INSPECTION
Inspect Catalytic converter for external cracks. Repair or replace as necessary.
BACK PRESSURE CHECK
If excessive exhaust back pressure is suspected, eliminate the exhaust system as a cause. If
exhaust back pressure remains excessive with all mufflers disconnected, the catalytic converter
may be plugged.
LOOSE CORE CHECK
If the exhaust system rattles during engine operation, check the catalytic converter for a loose core.
With the vehicle raised (for access), tap the catalytic converter with a rubber mallet. If the converter
rattles, the core is loose and the converter must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3584
Catalytic Converter: Component Tests and General Diagnostics
Catalytic Converter Functional Test
NOTE: If all other emission systems are functioning correctly, but vehicle still has excessive tailpipe
emissions, the catalytic converter core may by contaminated. To check converter effectiveness,
perform the following test:
FUNCTIONAL CHECK
1. Warm the engine to normal operating temperature. 2. Run the engine at 2500 RPM for 30
seconds. 3. Using a pyrometer, measure the exhaust pipe temperature before and after the
catalytic converter. 4. Exhaust pipe temperature should be at least 100° F hotter at the converter
outlet than at the inlet. 5. If catalytic converter has little or no effect on exhaust temperature, the
core may be contaminated.
NOTE: If exhaust temperature exceeds 450° F, the engine may be running too lean. Repair the
lean running condition and recheck exhaust temperature before condemning the catalytic
converter.
At Oxygen Sensor Opening
Pressure Testing The Exhaust System at The Oxygen Sensor
NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire
up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel
system problems, then perform a visual inspection of the exhaust system. If the condition cannot
be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT
OXYGEN SENSOR OPENING
1. Carefully remove O2 sensor using proper tool. 2. Install Exhaust Backpressure Tester in place of
02 sensor. 3. With the engine at normal operating temperature and running at 2500 rpm, observe
the exhaust system backpressure reading on gauge. 4. If backpressure exceeds 1-1/4 psi (8.62
kPa), a restricted exhaust system is indicated. 5. Inspect the entire exhaust system for a collapsed
pipe, heat distress, or possible internal muffler failure. 6. If there are no obvious reasons for the
excessive backpressure, a restricted catalytic converter should be suspected, and replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Catalytic Converter > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 3585
NOTE: Prior to installing O2 sensor:
- Clean threads in exhaust manifold with an 18 mm X 1.5 + 6E tap.
- Coat sensor threads with a nickel based anti-seize compound (Loctite 771-64 or equivalent). Do
not use graphite or other anti-seize compounds.
Using Manifold Vacuum Port
NOTE: A partially restricted or blocked exhaust system usually results in a loss of power or backfire
up through the throttle body. Verify that the condition is not caused by ignition, compression or fuel
system problems, then perform a visual inspection of the exhaust system. If the condition cannot
be located by visual inspection, perform the easiest of the following procedures. DIAGNOSIS AT
MANIFOLD VACUUM PORT
1. With engine at normal operating temperature, connect a vacuum gauge to any convenient
manifold vacuum source. 2. Run engine at 1,000 rpm and record vacuum reading. 3. Increase rpm
slowly to 2,500 rpm, and note vacuum reading at a steady 2.500 rpm. 4. If vacuum at 2,500 rpm
decreases more than 3" Hg, from reading at 1000 rpm, the exhaust system should be inspected for
restrictions. 5. Disconnect exhaust pipe from engine and repeat Step 3 & 4. If vacuum still drops
more than 3" Hg, with exhaust disconnected, check for exhaust
manifold restriction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Component Locations
Fig 49 Proportional Purge Solenoid
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Component Locations > Page 3591
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 3592
Canister Purge Solenoid: Description and Operation
Fig 49 Proportional Purge Solenoid
PURPOSE
All vehicles use a Proportional purge solenoid. The solenoid regulates the rate of vapor flow from
the EVAP canister to the throttle body. The PCM operates the solenoid.
OPERATION
During the cold start warm-up period and the hot start time delay, the PCM does not energize the
solenoid. When de-energized, no vapors are purged. The PCM de-energizes the solenoid during
open loop operation.
The proportional purge solenoid operates at a frequency of 200 hz and is controlled by an engine
controller circuit that senses the current being applied to the proportional purge solenoid and then
adjusts that current to achieve the desired purge flow. The proportional purge solenoid controls the
purge rate of fuel vapors from the vapor canister and fuel tank to the engine intake manifold.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Canister Purge Solenoid > Component Information > Locations > Page 3593
Canister Purge Solenoid: Service and Repair
Fig 49 Proportional Purge Solenoid
REMOVAL
1. Remove vacuum hose and electrical connector from solenoid. 2. Pull solenoid up to remove it
from mounting bracket.
INSTALLATION
Reverse above procedure for installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations
Evaporative Emission Control Canister: Locations
Fig 1 Evaporative Canister
All vehicles use a sealed, maintenance free, evaporative (charcoal) canister. The canister is
attached to the frame under the driver's seat (Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System >
Evaporative Emission Control Canister > Component Information > Locations > Page 3597
Evaporative Emission Control Canister: Description and Operation
Fig 1 Evaporative Canister
All vehicles use a sealed, maintenance free, evaporative (charcoal) canister. The canister is
attached to the frame under the driver's seat (Fig. 1).
Fuel tank vapor vents into the canister. The canister temporarily holds the fuel vapors until intake
manifold vacuum draws them into the combustion chamber. The canister proportional purge
solenoid allows the canister to be purged at predetermined intervals and engine conditions.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > EVAP System - Leak
Detection Pump Misdiagnosis
Leak Detection Pump: Technical Service Bulletins EVAP System - Leak Detection Pump
Misdiagnosis
NUMBER: 18-01-00
GROUP: Vehicle Performance
DATE: Feb. 4, 2000
SUBJECT: Misdiagnosed Leak Detection Pump Systems With DTC P1494, P0442, P0455, OR
P0456
MODELS: 1997 - 2000 (AB) Ram Van 1997 - 2000 (AN) Dakota 1997 - 2000 (BR/BE) Ram truck
1998 - 2000 (DN) Durango 1997 - 2000 (FJ) Avenger/Sebring/Talon 1997 - 2000 (JA)
Cirrus/Stratus/Breeze 1997 - 2000 (JX) Sebring Convertible 1997 - 2000 (LH)
Concorde/Intrepid/LHS/3OOMNision 1997 - 2000 (NS) Town & Country/CaravanNoyager 1997 2000 (PL) Neon 1997 - 2000 (PR) Prowler 1997 - 2000 (SR) ViperNiper GIS 1997 - 2000 (TJ)
Wrangler 1999 - 2000 (WJ) Grand Cherokee 1997 - 2000 (XJ) Cherokee 1997 - 1998 (ZJ)
GrandCherokee
DISCUSSION: During evaporative system diagnosis, Leak Detection Pumps have mistakenly been
replaced. A thorough inspection for pinched, kinked, or disconnected supply vacuum lines (as
currently listed in the Powertrain Diagnostic Procedures) is a critical step in diagnosing DTC P1494
(LDP SW OR MECHANICAL FAULT). Additionally, the other evaporative leak faults (DTC P0442 SMALL LEAK, P0455 - LARGE LEAK, and P0456 - VERY SMALL LEAK) should have the supply
vacuum lines examined for pinches or kinks prior to any LDP component replacement.
The supply vacuum lines should be checked from the engine compartment all the way to the fuel
tank, including the LDP and purge system.
NOTE:
VERIFY ALL RELATED SUPPLY VACUUM LINE ROUTINGS FOR PINCHES, KINKS, OR
DISCONNECTION'S BEFORE REPLACING LDP SYSTEM COMPONENTS.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3602
Leak Detection Pump: Locations
Evaporative Leak Detection Pump
The Leak Detection Pump (LDP) is located under the driver's side in the cast cradle under the
steering gear.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3603
Leak Detector Pump Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3604
Leak Detection Pump: Description and Operation
Leak Detection Pump (LDP) Operation And Diagnosis
This bulletin describes the theory of operation for the leak detection system. In addition, information
is provided for each of the Diagnostic Trouble Codes (DTC's) as follows:
P0442-EVAP LEAK MONITOR 0.040" LEAK DETECTED
P0455-EVAP LEAK MONITOR LARGE LEAK DETECTED
P0456-EVAP LEAK MONITOR 0.020" LEAK DETECTED
P1486-EVAP LEAK MONITOR PINCHED HOSE FOUND
P1494-LEAK DETECTION PUMP SW OR MECHANICAL FAULT
P1495-LEAK DETECTION PUMP SOLENOID CIRCUIT
INTRODUCTION
The evaporative emission system is designed to prevent the escape of fuel vapors from the fuel
system. Leaks in the system, even small ones, can allow fuel vapors to escape into the
atmosphere. Government regulations require on-board testing to make sure that the evaporative
(EVAP) system is functioning properly. The leak detection system tests for EVAP system leaks and
blockage. It also performs self-diagnostics.
During self-diagnostics, the Powertrain Control Module (PCM) first checks the Leak Detection
Pump (LDP) for electrical and mechanical faults. If the first checks pass, the PCM then uses the
LDP to seal the vent valve and pump air into the system to pressurize
it. If a leak is present, the PCM will continue pumping the LDP to replace the air that leaks out. The
PCM determines the size of the leak based on how fast/long it must pump the LDP as it tries to
maintain pressure in the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3605
EVAP LEAK DETECTION SYSTEM COMPONENTS
Service Port: Used with special tools like the Miller Evaporative Emissions Leak Detector (EELD) to
test for leaks in the system.
EVAP Purge Solenoid: The PCM uses the EVAP purge solenoid to control purging of excess fuel
vapors stored in the EVAP canister. It remains closed during leak testing to prevent loss of
pressure.
EVAP Canister The EVAP canister stores fuel vapors from the fuel tank for purging. EVAP Purge
Orifice: Limits purge volume.
EVAP System Air Filter: Provides air to the LDP for pressurizing the system. It filters out dirt while
allowing a vent to atmosphere for the EVAP system.
Leak Detection Pump (LDP) Components
The main purpose of the LDP is to pressurize the fuel system for leak checking. It closes the EVAP
system vent to atmospheric pressure so the system can be pressurized for leak testing. The
diaphragm is powered by engine vacuum. It pumps air into the EVAP system to develop a pressure
of about 7.5' H20(1/4) psi. A reed switch in the LDP allows the PCM to monitor the position of the
LDP diaphragm. The PCM uses the reed switch input to monitor how fast the LDP is pumping air
into the EVAP system. This allows detection of leaks and blockage.
The LDP assembly consists of several parts. The solenoid is controlled by the PCM, and it
connects the upper pump cavity to either engine vacuum or atmospheric pressure. A vent valve
closes the EVAP system to atmosphere, sealing the system during leak testing. The pump section
of the LDP consists of a diaphragm that moves up and down to bring air in through the air filter and
inlet check valve, and pump it out through an outlet check valve into the EVAP system.
The diaphragm is pulled up by engine vacuum, and pushed down by spring pressure, as the LDP
solenoid turns on and off. The LDP also has a magnetic reed switch to signal diaphragm position to
the PCM. When the diaphragm is down, the switch is closed, which sends a 12 V (system voltage)
signal to the PCM. When the diaphragm is up, the switch is open, and there is no voltage sent to
the PCM. This allows the PCM to monitor LDP pumping action as it turns the LDP solenoid on and
off.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3606
LDP AT REST (NOT POWERED)
When the LDP is at rest (no electrical/vacuum) the diaphragm is allowed to drop down if the
internal (EVAP system) pressure is not greater than the return spring. The LDP solenoid blocks the
engine vacuum port and opens the atmospheric pressure port connected through the EVAP system
air filter. The vent valve is held open by the diaphragm. This allows the canister to see atmospheric
pressure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3607
DIAPHRAGM UPWARD MOVEMENT
When the PCM energizes the LDP solenoid, the solenoid blocks the atmospheric port leading
through the EVAP air filter and at the same time opens the engine vacuum port to the pump cavity
above the diaphragm. The diaphragm moves upward when vacuum above the diaphragm exceeds
spring force. This upward movement closes the vent valve. It also causes low pressure below the
diaphragm, unseating the inlet check valve and allowing air in from the EVAP air filter. When the
diaphragm completes its upward movement, the LDP reed switch turns from closed to open.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3608
DIAPHRAGM DOWNWARD MOVEMENT based on reed switch input, the PCM de-energizes the
LDP solenoid, causing it to block the vacuum port, and open the atmospheric port. This connects
the upper pump cavity to atmosphere through the EVAP air filter. The spring is now able to push
the diaphragm down. The downward movement of the diaphragm closes the inlet check valve and
opens the outlet check valve pumping air into the evaporative system. The LDP reed switch turns
from open to closed, allowing the PGM to monitor LDP pumping (diaphragm up/down) activity.
During the pumping mode, the diaphragm will not move down far enough to open the vent valve
The pumping cycle is repeated as the solenoid is turned on and off. When the evaporative system
begins to pressurize, the pressure on the bottom of the diaphragm will begin to oppose the spring
pressure, slowing the pumping action. The PCM watches the time from when the solenoid is
de-energized, until the diaphragm drops down far enough for the reed switch to change from
opened to closed. If the reed switch changes too quickly, a leak may be indicated. The longer it
takes the reed switch to change state, the tighter the evaporative system is sealed. If the system
pressurizes too quickly, a restriction somewhere in the EVAP system may be indicated.
PUMPING ACTION During portions of this test, the PCM uses the reed switch to monitor
diaphragm movement. The solenoid is only turned on by the PCM after the reed switch changes
from open to closed, indicating that the diaphragm has moved down. At other times during the test,
the PCM will rapidly cycle the LDP solenoid on and off to quickly pressurize the system. During
rapid cycling, the diaphragm will not move enough to change the reed switch state. In the state of
rapid cycling, the PCM will use a fixed time interval to cycle the solenoid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3609
Leak Detection Pump: Testing and Inspection
ENABLING CONDITIONS TO RUN EVAP LEAK DETECTION TEST
NOTE: The following values are approximate and vehicle specific. Use the values seen in pre
test/monitor test screen on the DRB III. See TSB 25-02-98 for more detail
1. Cold start: with ambient temperature (obtained from modeling the inlet air temperature sensor on
passenger vehicles and the battery temperature sensor on Jeep & truck vehicles) between 4C° (40°
F) and 32° C (90° F) for 0.040 leak. Between 4C° (40° F) and 29° C (85° F) for 0.020 leak. 2.
Engine coolant temperature within:-12° to -8°C (10° to 18°F) of battery/ambient. 3. Battery voltage
between 10 and 15 volts.
NOTE: If battery voltage drops below 10 volts for more than 5 seconds during engine cranking, the
EVAP leak detection test will not run.
4. Low fuel warning light off (fuel level must be between 15% and 85% for 0.040 leak and 30% and
85% for 0.020 leak). 5. MAP sensor reading 22 in Hg or above (This is the manifold absolute
pressure, not vacuum). 6. No engine stall during test.
If the system does not pass the EVAP Leak Detection Test, the following DTCs may be set:
- P0442 - EVAP LEAK MONITOR 0.040" LEAK DETECTED
- P0455 - EVAP LEAK MONITOR LARGE LEAK DETECTED
- P0456 - EVAP LEAK MONITOR 0.020" LEAK DETECTED
- P1486 - EVAP LEAK MON PINCHED HOSE FOUND
- P1494 - LEAK DETECTION PUMP SW OR MECH FAULT
- P1495 - LEAK DETECTION PUMP SOLENOID CIRCUIT
A DTC will not be set if a one-trip fault is set or if MIL is illuminated for any of the following:
- Purge Solenoid Electrical Fault
- All Engine Controller Self Test Faults
- All Cam And/or Crank Sensor Fault
- All Map Sensor Faults
- Ambient/battery Temperature Sensor Electrical Faults
- All Coolant Sensor Faults
- All TPS Faults
- LDP Pressure Switch Fault
- EGR Solenoid Fault
- All Injector Faults
- Baro Our Of Range
- Vehicle Speed Faults
- LDP Solenoid Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3610
Figure 6
EVAP leak detection test sequence
When the ignition key is turned to "ON" the LDP diaphragm should be in the down position and the
LDP reed switch should be closed. If the EVAP system has residual pressure, the LDP diaphragm
may be up. This could result in the LDP reed switch being open when the key is turned to "ON" and
a P1494 fault could be set because the PCM is expecting the reed switch to be closed.
After the key is turned "ON", the PCM immediately tests the LDP solenoid circuit for electrical
faults. If a fault is detected, DTC P1495 will set, the MIL will illuminate, and the remaining EVAP
Leak Detection Test is canceled.
NOTE: If battery temperature is not within range, or if the engine coolant temperature is not within a
specified range of the battery temperature, the PCM will not run tests for DTC P1494, P1486,
P0442, P0455 and P0441. These temperature calibrations may be different between models.
FIGURE 6 SECTION 2
If DTC P1495 is not set, the PCM will check for DTC P1494. If the LDP reed switch was closed
when the key was turned to "ON", the PCM energizes the LDP solenoid for up to 8 seconds and
monitors the LDP switch. As the LDP diaphragm is pulled up by engine vacuum, the LDP reed
switch should change from closed to open. If it does not, the PCM sets a temporary fault (P1494) in
memory, and waits until the next time the Enabling Conditions are met to run the test again. If this
is again detected, P1494 is stored and the MIL is illuminated. If the problem is not detected during
the next enabling cycle, the temporary fault will be cleared.
However, if the PCM detects the reed switch open when the key is turned to "ON", the PCM must
determine if this condition is due to residual pressure in the EVAP system, or an actual fault. The
PCM stores information in memory on EVAP system purging from previous engine run or drive
cycles.
If little or no purging took place, residual pressure could be holding the LDP diaphragm up, causing
the LDP switch to be open. Since this is not a malfunction, the PCM cancels the EVAP Leak
Detection Test without setting the temporary fault.
If there was sufficient purging during the previous cycle to eliminate EVAP system pressure, the
PCM judges that this is a malfunction and sets a temporary fault in memory. The next time that the
Enabling Conditions are met, the test will run again. If the fault is again detected, the MIL will
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3611
illuminate and DTC 1494 will be stored. If the fault is not detected, the temporary fault will be
cleared.
FIGURE 6 SECTION 3
If no fault has been detected so far, the PCM begins testing for possible blockage in the EVAP
system between the LDP and the fuel tank. This is done by monitoring the time required for the
LDP to pump air into the EVAP system during two to three pump cycles. If no blockage is present,
the LDP diaphragm is able to quickly pump air out of the LDP each time the PCM turns oft the LDP
solenoid. If a blockage is present, the PCM detects that the LDP takes longer to complete each
pump cycle. If the pump cycles take longer than expected (approximately 6 to 10 seconds) the
PCM will suspect a blockage. On the next drive when Enabling Conditions are met, the test will run
again. If blockage is again detected, P1486 is stored, and the MIL is illuminated.
FIGURE 6 SECTION 4
After the LDP blockage tests are completed, the PCM then tests for EVAP system leakage. First,
the PCM commands the LDP to rapidly pump for 20 to 50 seconds (depending on fuel level) to
build pressure in the EVAP system. This evaluates the system J18-24-0 to see if it can be
sufficiently pressurized. This evaluation (rapid pump cycling) may occur several times prior to leak
checking. The LDP reed switch does not close and open during rapid pumping because the
diaphragm does not travel through its full range during this part of the test.
FIGURE 6 SECTION 5
Next, the PCM performs one or more test cycles by monitoring the time required for the LDP reed
switch to close (diaphragm to drop) after the LDP solenoid is turned off.
If the switch does not close, or closes after a long delay, it means that the system does not have
any significant leakage and the EVAP Leak Detection Test is complete.
However, if the LDP reed switch closes quickly, there may be a leak or the fuel level may be low
enough that the LDP must pump more to finish pressurizing the EVAP system. In this case, the
PCM will rapidly pump the LDP again to build pressure in the EVAP system, and follow that by
monitoring the time needed for several LDP test cycles. This process of rapid pumping followed by
several LDP test cycles may repeat several times before the PCM judges that a leak is present.
When leaks are present, the LDP test cycle time will be inversely proportional to the size of the
leak. The larger the leak, the shorter the test cycle time. The smaller the leak, the longer the test
cycle time. DTC's may be set when a leak as small as 0.5 mm (0.020") diameter is present.
If the system detects a leak, a temporary fault will be stored in PCM memory. The time it takes to
detect a .020, .040, or Large leak is based on calibrations that vary from model to model. The
important point to remember is if a leak is again detected on the next EVAP Leak Detection Test,
the MIL will illuminate and a DTC will be stored based on the size of leak detected. If no leak is
detected during the next test, the temporary fault will be cleared.
DIAGNOSTIC TIPS
During diagnosis, you can compare the LDP solenoid activity with the monitor sequence in Figure
6. If the PCM detects a problem that could set a DTC, the testing is halted and LDP solenoid
activity will stop. As each section of the test begins, it indicates that the previous section passed
successfully. By watching to see which tests complete, you can see if any conditions are present
that the PCM considers abnormal.
For example, if the LDP solenoid is energized for the test cycles to test for blockage (P1486), it
means that the LDP has already passed its test for P1494. Then, if the PCM detects a possible
blockage, it will set a temporary fault without turning on the MIL and continue the leak portion of the
test. However, the PCM will assume that the system is already pressurized and skip the rapid
pump cycles.
Always diagnose leaks, if possible, before disconnecting connections. Disconnecting connections
may mask a leak condition.
Keep in mind that if the purge solenoid seat is leaking, it could go undetected since the leak would
end up in the intake manifold. Disconnect the purge solenoid at the manifold when leak checking.
In addition, a pinched hose fault (P1486) could set if the purge solenoid does not purge the fuel
system properly (blocked seat). The purge solenoid must vent the fuel system prior to the LDP
system test. If the purge solenoid cannot properly vent the system the LDP cannot properly
complete the test for P1486 and this fault can set due to pressure being in the EVAP system during
the test sequence.
Multiple actuation's of the DRB Ill® Leak Detection Pump (LDP) Monitor Test can hide a 0.020 leak
because of excess vapor generation. Additionally, any source for additional vapor generation can
hide a small leak in the EVAP system. Excess vapor generation can delay the fall of the LDP
diaphragm thus hiding the small leak. An example of this condition could be bringing a cold vehicle
into a warm shop for testing or high ambient temperatures.
Fully plugged and partially plugged underhood vacuum lines have been known to set MIL
conditions. P1494 and P0456 can be set for this reason. Always, thoroughly, check plumbing for
pinches or blockage before condemning components.
TEST EQUIPMENT
The Evaporative Emission Leak Detector (EELD) Miller Special Tool 8404 is capable of visually
detecting leaks in the evaporative system and will take
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3612
the place of the ultrasonic leak detector 6917A. The EELD utilizes shop air and a smoke generator
to visually detect leaks down to 0.020 or smaller. The food grade oil used to make the smoke
includes an UV trace dye that will leave telltale signs of the leak under a black light. This is helpful
when components have to be removed to determine the exact leak location. For detailed test
instructions, follow the operators manual packaged with the EELD.
IMPORTANT
Be sure that the PCM has the latest software update. Reprogram as indicated by any applicable
Technical Service Bulletin. After LDP repairs are completed, verify the repair by running the DRB
Ill® Leak Detection Pump (LDP) Monitor Test as described in Technical Service Bulletin 18-12-99.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3613
Leak Detection Pump: Service and Repair
Fig 9 Leak Detection Pump
NOTE: The Leak Detection Pump (LDP) is located under the driver's side in the cast cradle under
the steering gear (Fig. 9).
REMOVAL
1. Raise and support vehicle on a hoist.
Fig 10 Leak Detection Pump Connector Lock
2. Push locking tab on connector to unlock (Fig. 10). 3. Push down on connector latch and pull
connector from pump. 4. Remove hoses. 5. Remove bolts holding LDP and bracket to cradle. 6.
Remove bracket from LDP.
INSTALLATION
1. Install LDP to bracket. 2. Install LDP and bracket to cradle. Torque bolts to 9.5-14 Nm (85-125 in
lb).
- Before installing hoses to LDP, make sure they are not cracked or split.
- If a hose leaks, it will cause the Check Engine Lamp to illuminate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Evaporative Emissions System > Leak
Detection Pump, Evaporative System > Component Information > Technical Service Bulletins > Page 3614
3. Install hoses to LDP. 4. Plug electrical connector into LDP. 5. Push connector locking tab into
place. 6. Using DRB scan tool, verify proper operation of LDP.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Locations
EGR Backpressure Transducer: Locations
EGR Solenoid And Valve
Electric EGR Transducer (EET)
EGR System
Mounted near the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Locations > Page 3619
EGR Backpressure Transducer: Description and Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electric EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
When the solenoid is de-energized the transducer varies the amount of vacuum routed to the EGR
valve control nipple, (depending on engine load conditions).
OPERATION
Transducer is supplied ported vacuum through the solenoid.
Transducer is a variable vacuum bleed valve, controlled by exhaust backpressure. When there is no exhaust backpressure, the vacuum bleed valve is completely open, and no
vacuum is applied to the EGR valve.
- When exhaust backpressure is great enough, it closes the vacuum bleed valve completely, and
maximum vacuum is applied to the EGR valve.
- When exhaust backpressure is present, but not great enough to close the vacuum bleed valve
completely, the vacuum applied to the EGR valve varies with the backpressure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Locations > Page 3620
EGR Backpressure Transducer: Testing and Inspection
TESTING ELECTRICAL SOLENOID PORTION OF VALVE
This is not to be used as a complete test of the EGR system.
Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to
the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly
Fig 4 EGR System
TESTING VACUUM TRANSDUCER PORTION OF VALVE
NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure
side of the valve has ruptured or is leaking. The second part of the test will determine if engine
vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used
as a complete test of the EGR system.
1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2.
Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If
vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to
next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the
EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to
operating temperature.
- Hold engine speed at approximately 1,500 rpm.
9. Check for steady engine vacuum (full-manifold) at this hose.
10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as
necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet
fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4)
on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical
connector (Fig. 4) at the valve control.
- This will simulate an open circuit (no ground from the PCM) at the valve.
15. Start the engine and bring to operating temperature. 16. Hold the engine speed to
approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting.
- To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present
at valve.
- It must be high enough to hold the bleed valve in the transducer portion of the valve closed.
- Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some
exhaust back-pressure while observing the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Locations > Page 3621
vacuum gauge.
- Heavy gloves should be worn.
CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to
components or overheating may result.
17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum
outlet fitting.
- Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low.
- This low reading is normal.
- At idle speed, the gauge reading will be erratic.
- This is also normal.
18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting,
replace the valve.
NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Backpressure Transducer > Component Information > Locations > Page 3622
EGR Backpressure Transducer: Service and Repair
EGR Mounting
REMOVAL
1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for
any damage.) 2. Remove EGR valve to intake manifold bolts. 3. Open transducer clip and remove
transducer. 4. Remove EGR valve. 5. Clean gasket surface and discard old gasket. 6. Inspect for
signs of leakage or cracks.
INSTALLATION
1. Loosely install EGR valve with new gasket. 2. Torque bolts to 200 in lb (22 Nm). 3. Install
transducer in clip with orientation tab in slot and snap closed. 4. Connect vacuum hose and
electrical connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Component Locations
EGR Control Solenoid: Component Locations
EGR Solenoid And Valve
Electric EGR Transducer (EET)
EGR System
Mounted near the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Component Locations > Page 3627
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 3628
EGR Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 3629
EGR Control Solenoid: Description and Operation
EGR Mounting
Electric EGR Transducer (EET)
NOTE: The Electronic EGR Transducer (EET) assembly is a vacuum control solenoid and a
backpressure transducer, in one package. PURPOSE
The PCM controls when the EGR valve can be actuated, through the solenoid valve portion of the
EET.
OPERATION
Ported vacuum from the throttle body, is supplied to the solenoid valve.
The PCM controls the flow of vacuum between the throttle body and the back pressure transducer,
(through the solenoid ground circuit).
- When the solenoid is energized (grounded), no vacuum is supplied to the transducer.
- When the solenoid is de-energized (not grounded), vacuum is supplied to the transducer.
The solenoid will always be energized (no EGR), under following conditions:
- Engine warm-up, (engine coolant temperature below 40 ~F)
- Engine at idle
- Wide Open Throttle (WOT) operation
- Rapid acceleration/deceleration
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 3630
- During EGR system diagnostic check
NOTE: If the wiring or connector is disconnected from the solenoid, the EGR valve will operate at
all times, (adversely affecting engine idle and performance).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 3631
EGR Control Solenoid: Testing and Inspection
TESTING ELECTRICAL SOLENOID PORTION OF VALVE
This is not to be used as a complete test of the EGR system.
Electrical operation of the valve should be checked with the DRB or equivalent scan tool. Refer to
the appropriate procedures. Replace solenoid if necessary, unit serviced only as an assembly
Fig 4 EGR System
TESTING VACUUM TRANSDUCER PORTION OF VALVE
NOTE: The first part of this test will determine if the transducer diaphragm at the back-pressure
side of the valve has ruptured or is leaking. The second part of the test will determine if engine
vacuum (full-manifold) is flowing from the inlet to the outlet side of the valve. This is not to be used
as a complete test of the EGR system.
1. Disconnect the rubber back-pressure hose from the fitting at the bottom of EGR valve (Fig. 4). 2.
Connect a hand-held vacuum pump to this fitting. 3. Apply 10 inches of vacuum to this fitting. 4. If
vacuum falls off, the valve diaphragm is leaking. 5. Replace the EGR valve assembly. Proceed to
next step for further testing. 6. Remove the rubber hose at the vacuum inlet fitting (Fig. 4) on the
EGR valve. 7. Connect a vacuum gauge to this disconnected hose. 8. Start the engine and bring to
operating temperature.
- Hold engine speed at approximately 1,500 rpm.
9. Check for steady engine vacuum (full-manifold) at this hose.
10. If engine vacuum (full-manifold) is not present, check vacuum line to engine and repair as
necessary before proceeding to next step. 11. Reconnect the rubber hose to the vacuum inlet
fitting (Fig. 4) on the EGR valve. 12. Disconnect the rubber hose at the vacuum outlet fitting (Fig. 4)
on the EGR valve. 13. Connect a vacuum gauge to this fitting. 14. Disconnect the electrical
connector (Fig. 4) at the valve control.
- This will simulate an open circuit (no ground from the PCM) at the valve.
15. Start the engine and bring to operating temperature. 16. Hold the engine speed to
approximately 2,000 rpm while checking for engine vacuum (full-manifold) at this fitting.
- To allow full manifold vacuum to flow through the valve, exhaust back-pressure must be present
at valve.
- It must be high enough to hold the bleed valve in the transducer portion of the valve closed.
- Have a helper momentarily (a second or two) hold a rag over the tailpipe opening to build some
exhaust back-pressure while observing the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Control Solenoid > Component Information > Locations > Page 3632
vacuum gauge.
- Heavy gloves should be worn.
CAUTION: Do not cover the tailpipe opening for an extended period of time as damage to
components or overheating may result.
17. As temporary back-pressure is built, full manifold vacuum should be observed at the vacuum
outlet fitting.
- Without back-pressure, and engine at approximately 2,000 rpm, the gauge reading will be low.
- This low reading is normal.
- At idle speed, the gauge reading will be erratic.
- This is also normal.
18. If full manifold vacuum is not present at the outlet fitting, but was present at the inlet fitting,
replace the valve.
NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Tube > Component Information > Service and Repair
EGR Tube: Service and Repair
Fig 6 EGR Tube
REMOVAL
1. Remove EGR tube attaching bolts from intake and exhaust manifolds (Fig. 6). 2. Clean intake
and exhaust manifold gasket surfaces. Discard old gasket. 3. Check for signs of leakage or
cracked surfaces on either manifolds or tube. Repair or replace as necessary.
INSTALLATION
1. Loosely assemble EGR tube and new gaskets into place on intake and exhaust manifolds. 2.
Tighten mounting bolts to 22 Nm (200 in lb) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Specifications
EGR Valve: Specifications
EGR Tube to Intake Manifold Screws
....................................................................................................................................................... 22
Nm (200 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Specifications > Page 3639
EGR Valve: Locations
EGR Solenoid And Valve
Valve and transducer, mounted near throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Specifications > Page 3640
EGR Valve: Testing and Inspection
Fig 4 EGR System
EGR VALVE LEAKAGE TEST
This is not to be used as a complete test of the EGR system.
If the engine will not idle, dies out on idle, or idle is rough or slow, the poppet valve (Fig. 4) at the
base of the EGR valve may be leaking in the closed position.
1. The engine should be off for the following test. 2. Disconnect the rubber hose from the fitting
(Fig. 4) at the top (vacuum motor) side of the EGR valve.
a. Connect a hand-held vacuum pump to this fitting. b. Apply 15 inches of vacuum to the pump. c.
Observe the gauge reading on the pump. d. If vacuum falls off, the diaphragm in the EGR valve
has ruptured. e. Replace the EGR valve. Note: The EGR valve, valve control and attaching hoses
are serviced as one assembly. f.
Proceed to the next step.
3. A small metal fitting (back-pressure fitting) is located at the base of the EGR valve (Fig. 4).
- A rubber back-pressure hose connects it to the back-pressure fitting on the EGR valve control.
- Disconnect this rubber hose at the EGR valve fitting.
4. Remove the air cleaner housing from the throttle body 5. Using compressed air, and an air
nozzle with a rubber tip, apply approximately 50 psi of regulated shop air to the metal
back-pressure fitting on
the EGR valve.
6. By hand, open the throttle to the wide open position.
- Air SHOULD NOT BE HEARD emitting from the intake manifold while applying air pressure at the
back-pressure fitting.
7. If air CAN BE HEARD emitting from the intake manifold, the poppet valve (Fig. 4) is leaking at
the bottom of the EGR valve.
- Replace the EGR valve.
NOTE: The EGR valve, valve control and attaching hoses are serviced as one assembly. Do not
attempt clean the old EGR valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Exhaust Gas Recirculation > EGR
Valve > Component Information > Specifications > Page 3641
EGR Valve: Service and Repair
Fig 5 EGR System
EGR Mounting
NOTE: The EGR valve and Electrical EGR Transducer are serviced as an assembly.
REMOVAL
1. Disconnect EGR transducer electrical connector and vacuum hose. (Inspect vacuum hose for
any damage (Fig. 5). 2. Remove electrical connector from solenoid. 3. Remove EGR valve bolts
from intake manifold. 4. Open EGR transducer clip and remove electric EGR transducer. 5.
Remove EGR valve from intake manifold. 6. Clean gasket surface and discard old gasket. Check
for any signs of leakage or cracked surfaces.
- Repair or replace as necessary.
INSTALLATION
1. Assemble EGR valve with new gasket onto the intake manifold. 2. Install mounting bolts. Tighten
bolts to 22 Nm (200 in lb) torque. 3. Install electric EGR transducer in clip with orientation tab in slot
and snap closed. 4. Reconnect vacuum hose and electrical connector to electrical EGR transducer.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component
Information > Description and Operation
Fillpipe Restrictor: Description and Operation
Fill Pipe Restrictor
PURPOSE
Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter
with lead.
Flapper controls evaporation of fuel during the time the filler cap is removed.
OPERATION
The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted.
INSPECTION
Use dowel gauge to check opening.
Look for; tampering, broken flapper, excessive wear etc..
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Fillpipe Restrictor > Component
Information > Description and Operation > Page 3645
Fillpipe Restrictor: Testing and Inspection
Fill Pipe Restrictor
Use dowel gauge to check restrictor opening [1].
Inspect for; tampering, broken flapper, excessive wear etc..
Remarks
[1] N&W; Manufacturing part number ---> FRG-95, or equivalent, (must be made of non-sparking
material, 1552 alloy suggested).
- Minimum tool diameter 0.9375"
- Maximum tool diameter 0.9500"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Crankcase Filter > Component Information > Description and Operation
Crankcase Filter: Description and Operation
This engine uses filtered air to vent the crankcase. The filtered air is drawn through the resonator
assembly located between the air cleaner and throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations
Fig 5 PCV Valve
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3653
Positive Crankcase Ventilation Valve: Description and Operation
Engine Off Or Engine Backfire - No Vapor Flow
The PCV valve contains a spring loaded plunger. This plunger meters the amount of crankcase
vapors routed into combustion chamber based on intake manifold vacuum.
When the engine is not operating, or during an engine backfire, the spring forces the plunger back
against the seat. This prevents vapors from flowing through the valve.
High Intake Manifold Vacuum - Minimal Vapor Flow
When engine is at idle or cruising, high manifold vacuum is present. At these times, manifold
vacuum is able to completely compress spring and pull plunger to top of valve. In this position,
there is minimal vapor flow through the valve.
Moderate Intake Manifold Vacuum - Maximum Vapor Flow
During periods of moderate intake manifold vacuum, the plunger is only pulled part way back from
the inlet. This results in maximum vapor flow through the valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Emission Control Systems > Positive Crankcase Ventilation >
Positive Crankcase Ventilation Valve > Component Information > Locations > Page 3654
Positive Crankcase Ventilation Valve: Testing and Inspection
Fig 8 PCV Test -- Typical
WARNING: Apply parking brake and/or block wheels before performing any test or adjustment with
the engine operating.
With the engine idling, remove the PCV valve from its attaching point. If the valve is operating properly, a hissing noise will he heard and a strong vacuum felt when
placing a finger over the valve inlet (Fig. 8).
With the engine off, shake the valve. The valve should rattle when shaken.
- Replace the valve if it does not operate properly.
NOTE: Do not attempt to clean the PCV valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations > Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure > Fuel Pressure
Test Port > Component Information > Locations > Compressed Natural Gas > Page 3661
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Release > System
Information > Service and Repair > CNG Engine > Page 3666
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications
Idle Speed: Specifications
Minimum Air Flow Idle Odometer <= 1000 Miles .................................................................................
.................................................................................................. 525-875 rpm Odometer >= 1000
Miles ....................................................................................................................................................
............................... 575-875 rpm
Note: Idle speed range achieved through Minimum Air Flow Idle Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 3670
Idle Speed: Testing and Inspection
THROTTLE BODY MINIMUM AIR FLOW CHECK
Fig 97 Air Metering Fitting 6457
Fig 100 PCV Valve
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the
intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457
(0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from
the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link
connector.
10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The
following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
airflow is set correctly.
2.4L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 500-875 RPM
Above 1000 Miles 550-875 RPM
3.0L Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 560-910 RPM
Above 1000 Miles 610-910 RPM
3.3L/3.8L Idle Specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed > System Information
> Specifications > Page 3671
Odometer Reading Idle RPM
Below 1000 Miles 525-875 RPM
Above 1000 Miles 575-875 RPM
14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let
Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash
thoroughly after using cleaner.
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle
purge line. 18. Remove DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air/Fuel Mixture > System
Information > Specifications
Air/Fuel Mixture: Specifications
The Air/Fuel Ratio is controlled by the Powertrain Control Module (PCM) and is not adjustable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications
Accelerator Pedal: Specifications
Accelerator Pedal to Dash Nuts ..........................................................................................................
....................................................... 12 Nm (105 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Accelerator Pedal > Component
Information > Specifications > Page 3678
Accelerator Pedal: Service and Repair
Fig 58 Accelerator Pedal And Throttle Cable -- Front View
Fig 59 Accelerator Pedal And Throttle Cable -- Rear View
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not
damage or kink the core wire inside the cable sheathing.
REMOVAL
1. Working from the engine compartment, hold the throttle body throttle lever in the wide open
position. Remove the throttle cable from the throttle
body cam.
2. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from
the upper end of the pedal shaft (Fig. 58) and (Fig.
59).
3. Working from the engine compartment, remove nuts from accelerator pedal attaching studs (Fig.
58). Remove assembly from vehicle.
INSTALLATION
1. Position accelerator pedal assembly on dash panel. Install retaining nuts. Tighten retaining nuts
to 12 Nm (105 in lb) torque. 2. From inside the vehicle, hold up the pedal and install the throttle
cable and cable retainer in the upper end of the pedal shaft. 3. From the engine compartment, hold
the throttle body lever in the wide open position and install the throttle cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair
Air Filter Element: Service and Repair
Fig 125 Air Inlet Resonator
REMOVAL
1. Remove 2 screws and air inlet resonator (Fig. 125). 2. Loosen 3 clamps holding air cleaner
housing halves together.
Fig 126 Air Cleaner Housing (Left Side)
3. Remove left side of air cleaner housing (Fig. 126).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Air Cleaner Housing > Air Filter
Element > Component Information > Service and Repair > Page 3683
Fig 127 Air Cleaner Element
4. Remove element from air cleaner housing (Fig. 127).
INSTALLATION
1. Install a new element in housing. 2. Position left side of housing. 3. Snap clamps into place. 4.
Install hoses and air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component
Information > Description and Operation
Fillpipe Restrictor: Description and Operation
Fill Pipe Restrictor
PURPOSE
Prevents the addition of leaded fuel, which would coat the oxygen sensor, and catalytic converter
with lead.
Flapper controls evaporation of fuel during the time the filler cap is removed.
OPERATION
The smaller fill pipe center opening prevents leaded fuel nozzles from be inserted.
INSPECTION
Use dowel gauge to check opening.
Look for; tampering, broken flapper, excessive wear etc..
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fillpipe Restrictor > Component
Information > Description and Operation > Page 3687
Fillpipe Restrictor: Testing and Inspection
Fill Pipe Restrictor
Use dowel gauge to check restrictor opening [1].
Inspect for; tampering, broken flapper, excessive wear etc..
Remarks
[1] N&W; Manufacturing part number ---> FRG-95, or equivalent, (must be made of non-sparking
material, 1552 alloy suggested).
- Minimum tool diameter 0.9375"
- Maximum tool diameter 0.9500"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Recalls: > 743 > Oct > 97 > Recall - Owners Manual
Technical Service Bulletin # 743 Date: 971001
Recall - Owners Manual
No. 743
October, 1997
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 743 -- Owner's Manual Addendum
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Built Through:
^ July 31, 1997 (MDH 073120) at the Windsor Assembly Plant ("R" in the 11th VIN Position); or
^ August 1, 1997 (MDH 080122) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
Reference: Service Action # 97-28 electronic mail (DMAIL) message on this subject.
The enclosed owner notification and Owner's Manual Addendum card are being mailed to all
owners of affected 1998 model year minivans. The addendum provides additional information on
how to identify those minivans that can be operated on ethanol (E85) fuel. Only minivans equipped
with a 3.3L engine (Sales Code -- EGM) and a Federal emission control system (Sales Code -NAA) are capable of operating on ethanol fuel (E85). These vehicles can be identified by the label
on the fuel filler door which states "ETHANOL (E85) OR UNLEADED GASOLINE ONLY". Use of
E85 in vehicles not designed to use E85, may cause fuel system damage and poor driveability.
Dealers are requested to enclose an addendum card in the Owner's Manual of each affected 1998
minivan in dealer stock before retail delivery. Each involved dealer to whom vehicles in the recall
were invoiced (or the current dealer at the same street address), will receive enough addendum
cards (included with the vehicle list) to service 100% of unsold vehicles according to our records. If
additional addendum cards are required, dealers may copy and cut out the enclosed addendum
card.
Owner Letter
OWNER'S MANUAL CORRECTION -- ETHANOL (E85) FUEL USAGE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, owners of 1998
Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town &
Country minivans are being provided with an Owner's Manual Addendum card.
A paragraph was inadvertently omitted from your vehicle's Owner's Manual. This omission makes it
appear that all 1998 Chrysler minivans are capable of operating on ethanol (E85) fuel. This is
incorrect. Only minivans equipped with a 3.3L V-6 engine and a Federal emission control system
can be operated on E85. These vehicles can be identified by the label ETHANOL (E85) OR
UNLEADED GASOLINE ONLY" on the fuel filler door. Use of E85 in vehicles not designed to use
E85 may cause fuel system damage and poor driveability.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > Recalls: > 743 > Oct > 97 > Recall - Owners Manual > Page 3696
Please retain the addendum card for future reference. We suggest that you staple it to the
appropriate page (listed on the addendum) of your Owner's Manual that is located in the glove box
of your vehicle.
Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability
Index Fuels
Fuel: All Technical Service Bulletins Engine - High Driveability Index Fuels
NO: 14-08-97
GROUP: Fuel
DATE: Nov. 21, 1997
SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel
MODELS:
1996 - 1998 (AB) Ram Van/Wagon
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1996 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (PL) Neon
1997 (PR) Prowler
1996 - 1998 (SR) Viper Roadster/Coupe
1997 - 1998 (TJ) Wrangler
1996 - 1998 (XJ) Cherokee
1995 - 1998 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are
most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80
degrees F).
DISCUSSION:
Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a
measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is
less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI
index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for
vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI
gasolines also cause higher emissions for the same reasons they cause driveability problems.
For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly
required. Using premium fuel with a higher than recommended octane rating is not recommended.
Owners who experience fuel related cold start and warm up driveability problems should try a
gasoline with the recommended octane rating or different brands of gasoline until they find one that
provides good performance.
The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher
than recommended octane gasoline under normal operating conditions does NOT improve
startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In
fact, most higher octane gasolines available in the U.S. have higher DI values than regular
gasoline. Customers are most likely to experience poor driveability with premium gasoline than with
regular.
Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC
Neon have been specifically designed to take advantage of higher octane. These vehicles may
have higher compression ratios, and/or more aggressive spark calibrations which provide optimum
performance with the specified higher octane. However, other vehicles which are not specifically
designed and calibrated to take advantage of higher octane will not benefit from higher octane.
Some vehicles may experience light spark knock in situations such as trailer towing or climbing
steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the
customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or
even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing
heavy spark knock on gasoline with its designed octane rating, this may be an indication of
excessive combustion chamber deposits, or some other problem. Combustion chamber deposits
can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic
procedures may help in identifying other potential causes of excessive knock.
Some gasoline marketers may advertise that their premium gasoline contains extra detergent
additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain
effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are
suspected of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability
Index Fuels > Page 3702
contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is
a much less expensive way to maintain engine cleanliness than regular use of premium gasoline.
The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer
satisfaction.
If fuel quality is suspected in causing a customers driveability concern, your zone technical office
may be able to provide direction on procedures for fuel sample analysis.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 743 > Oct > 97 > Recall - Owners Manual
Technical Service Bulletin # 743 Date: 971001
Recall - Owners Manual
No. 743
October, 1997
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 743 -- Owner's Manual Addendum
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Built Through:
^ July 31, 1997 (MDH 073120) at the Windsor Assembly Plant ("R" in the 11th VIN Position); or
^ August 1, 1997 (MDH 080122) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
Reference: Service Action # 97-28 electronic mail (DMAIL) message on this subject.
The enclosed owner notification and Owner's Manual Addendum card are being mailed to all
owners of affected 1998 model year minivans. The addendum provides additional information on
how to identify those minivans that can be operated on ethanol (E85) fuel. Only minivans equipped
with a 3.3L engine (Sales Code -- EGM) and a Federal emission control system (Sales Code -NAA) are capable of operating on ethanol fuel (E85). These vehicles can be identified by the label
on the fuel filler door which states "ETHANOL (E85) OR UNLEADED GASOLINE ONLY". Use of
E85 in vehicles not designed to use E85, may cause fuel system damage and poor driveability.
Dealers are requested to enclose an addendum card in the Owner's Manual of each affected 1998
minivan in dealer stock before retail delivery. Each involved dealer to whom vehicles in the recall
were invoiced (or the current dealer at the same street address), will receive enough addendum
cards (included with the vehicle list) to service 100% of unsold vehicles according to our records. If
additional addendum cards are required, dealers may copy and cut out the enclosed addendum
card.
Owner Letter
OWNER'S MANUAL CORRECTION -- ETHANOL (E85) FUEL USAGE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, owners of 1998
Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager; and Chrysler Town &
Country minivans are being provided with an Owner's Manual Addendum card.
A paragraph was inadvertently omitted from your vehicle's Owner's Manual. This omission makes it
appear that all 1998 Chrysler minivans are capable of operating on ethanol (E85) fuel. This is
incorrect. Only minivans equipped with a 3.3L V-6 engine and a Federal emission control system
can be operated on E85. These vehicles can be identified by the label ETHANOL (E85) OR
UNLEADED GASOLINE ONLY" on the fuel filler door. Use of E85 in vehicles not designed to use
E85 may cause fuel system damage and poor driveability.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Fuel: > 743 > Oct > 97 > Recall - Owners Manual > Page
3707
Please retain the addendum card for future reference. We suggest that you staple it to the
appropriate page (listed on the addendum) of your Owner's Manual that is located in the glove box
of your vehicle.
Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability Index
Fuels
Fuel: All Technical Service Bulletins Engine - High Driveability Index Fuels
NO: 14-08-97
GROUP: Fuel
DATE: Nov. 21, 1997
SUBJECT: Poor Driveability With High DI (Driveability Index) Fuel
MODELS:
1996 - 1998 (AB) Ram Van/Wagon
1996 - 1998 (AN) Dakota
1996 - 1998 (BR/BE) Ram Truck
1998 (DN) Durango
1996 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1996 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (PL) Neon
1997 (PR) Prowler
1996 - 1998 (SR) Viper Roadster/Coupe
1997 - 1998 (TJ) Wrangler
1996 - 1998 (XJ) Cherokee
1995 - 1998 (ZJ) Grand Cherokee
SYMPTOM/CONDITION:
Long cold start times, warm-up sags, hesitations, and driveway die outs. These symptoms are
most noticeable and severe at moderate ambient temperatures between 4 - 27 degrees C (40 - 80
degrees F).
DISCUSSION:
Gasoline with a high Driveability Index (DI) can cause the above described symptoms. DI is a
measure of the gasolines total volatility, or tendency to vaporize completely. A high DI number is
less volatile than a low DI number. Most premium gasoline sold in the U.S. has a higher (worse) DI
index than regular or mid-grade gasoline. Use of premium gasoline is NOT recommended for
vehicles designed to run on 87 (R+M)/2 regular or 89 (R+M)/2 midgrade gasoline. High DI
gasolines also cause higher emissions for the same reasons they cause driveability problems.
For vehicles that require an octane rating of 91 (R+M)/2, premium is recommended, or possibly
required. Using premium fuel with a higher than recommended octane rating is not recommended.
Owners who experience fuel related cold start and warm up driveability problems should try a
gasoline with the recommended octane rating or different brands of gasoline until they find one that
provides good performance.
The octane quality of gasoline is only a measure of its resistance to spark knock. The use of higher
than recommended octane gasoline under normal operating conditions does NOT improve
startability, idle quality, fuel economy, driveability, acceleration, engine durability, or emissions. In
fact, most higher octane gasolines available in the U.S. have higher DI values than regular
gasoline. Customers are most likely to experience poor driveability with premium gasoline than with
regular.
Some vehicles, such as Viper, Prowler, 5.9L Grand Cherokee, 2.0L Turbo Talon, and 2.0L DOHC
Neon have been specifically designed to take advantage of higher octane. These vehicles may
have higher compression ratios, and/or more aggressive spark calibrations which provide optimum
performance with the specified higher octane. However, other vehicles which are not specifically
designed and calibrated to take advantage of higher octane will not benefit from higher octane.
Some vehicles may experience light spark knock in situations such as trailer towing or climbing
steep sustained grades. Light knock or "ping" under these conditions is not harmful. However, if the
customer is concerned about light knock under these circumstances, the use of 89 (R+M)/2 or
even 91 (R+M)/2 premium gasoline may be temporarily warranted. If a vehicle is experiencing
heavy spark knock on gasoline with its designed octane rating, this may be an indication of
excessive combustion chamber deposits, or some other problem. Combustion chamber deposits
can be removed with Mopar Combustion Chamber Conditioner p/n 04318001. Standard diagnostic
procedures may help in identifying other potential causes of excessive knock.
Some gasoline marketers may advertise that their premium gasoline contains extra detergent
additives. Under provisions of the Clean Air Act, ALL gasoline sold in the U.S. must contain
effective deposit control additives. Nevertheless, if fuel injector or intake valve deposits are
suspected of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Technical Service Bulletins > All Other Service Bulletins for Fuel: > 14-08-97 > Nov > 97 > Engine - High Driveability Index
Fuels > Page 3713
contributing to poor performance, occasional use of Mopar Fuel Injector Clean Up p/n 04549613 is
a much less expensive way to maintain engine cleanliness than regular use of premium gasoline.
The charts (Figures 1 & 2) show the negative effects of high DI fuel as related to customer
satisfaction.
If fuel quality is suspected in causing a customers driveability concern, your zone technical office
may be able to provide direction on procedures for fuel sample analysis.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Gasoline Engines
Fuel: Specifications Gasoline Engines
FUEL REQUIREMENTS
The vehicle is designed to meet all emission regulations and provide excellent fuel economy when
using high quality unleaded gasoline having a minimum octane rating of 87.
The vehicle will operate on fuels ranging from regular unleaded having a minimum posted octane
of 87 to premium unleaded with a minimum posted octane of 91. However, mid-grade unleaded
fuel with a minimum octane rating of 89 is recommended. The use of premium unleaded gasoline
will further improve performance.
If the vehicle develops occasional light spark knock (ping) at low engine speeds this is not harmful.
However; continued heavy spark knock at high speeds can cause damage and should be corrected
immediately. Engine damage as a result of heavy spark knock operation may not be covered by
the new vehicle warranty.
In addition to using unleaded gasoline with the proper octane rating, those that contain detergents,
corrosion and stability additives are recommended. Using gasoline that has these additives will
help improve fuel economy, reduce emissions, and maintain vehicle performance.
Poor quality gasoline can cause problems such as hard starting, stalling, and stumble. If you
experience these problems, try another brand of gasoline before considering service for the
vehicle.
ADDITIVES & OXYGENATE BLENDS
Additives - The use of gasoline containing detergents, corrosion and stability additives is
recommended, as these additives will improve fuel economy, reduce emissions, and maintain
vehicle performance.
Fuel Quality - Poor quality gasoline can cause problems such as hard starting, stalling, and
stumble. If you experience these problems, try another brand of gasoline before considering
service for the vehicle.
Pinging/Knocking - Light knock at low engine speeds is not harmful to your engine. However,
continued heavy spark knock at high speeds can cause damage and should be reported to your
dealer immediately.
CAUTION: Engine damage resulting from operating with a heavy spark knock may not be covered
by the new vehicle warranty.
GASOLINE/OXYGENATE BLENDS
Ethanol - (Ethyl or Grain Alcohol) properly blended, is used as a mixture of 10 percent ethanol and
90 percent gasoline. Gasoline blended with ethanol may be used in your vehicle.
Methanol - (Methyl or Wood Alcohol) is used in a variety of concentrations when blended with
unleaded gasoline. You may find fuels containing 3 percent or more methanol along with other
alcohols called cosolvents.
CAUTION: Do not use gasoline containing Methanol. Use of methanol/gasoline blends may result
in starting and driveability problems and damage critical fuel system components. Problems that
are the result of using methanol/gasoline blends may not be covered by the new vehicle warranty.
CLEAN AIR GASOLINE
MTBE/ETBE - Many gasoline are now being blended that contribute to cleaner air, especially in
those areas of the country where pollution levels are high. These new blends provide a cleaner
burning fuel and some are referred to as reformulated gasoline..
MTBE (Methyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to 15 percent
MTBE. Gasoline blended with MTBE may be used in your vehicle.
ETBE (Ethyl Tertiary Butyl Ether) blends are a mixture of unleaded gasoline and up to up to 17
percent ETBE. Gasoline blended with ETBE may be used in your vehicle.
ADDITIVE CAUTION: Many materials intended for gum and varnish removal may contain active
solvents or similar ingredients that can be harmful to fuel system gasket and diaphragm materials.
Indiscriminate use of fuel system cleaning agents should be avoided.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel > Component Information >
Specifications > Gasoline Engines > Page 3716
Fuel: Specifications Flexible Fuel Engines
E-85 GENERAL INFORMATION
This information applies only to components or subjects that are specific to Flexible Fuel Vehicles
(FFV) only. These vehicles can be identified by the unique Fuel Filler Door Label that states
"Ethanol (E-85) or Unleaded Gasoline Only".
ETHANOL FUEL (E-85)
E-85 is a mixture of approximately 85% fuel ethanol and 15% unleaded gasoline.
WARNING: Ethanol vapors are extremely flammable and could cause serious personal injury.
Never have any smoking materials lit in or near the vehicle when removing the fuel filler cap (gas
cap) or filling the tank. Do not use E-85 as a cleaning agent and never use E-85 near and open
flame.
FUEL REQUIREMENTS
This vehicle will operate on both unleaded gasoline with an octane rating of 87, or E-85 fuel, or any
mixture of these two fuels.
For best results, a refueling pattern that alternates between E-85 and unleaded gasoline should be
avoided. When you do switch fuels, it is recommended that: You do not switch when the fuel gauge indicates less than 1/4 tank.
- You do not add less than 5 gallons when refueling.
- You operate the vehicle immediately after refueling for a period of at least 5 minutes.
Observing these precautions will avoid possible hard starting and / or significant deterioration in
driveablity during warm up.
NOTE: When the ambient temperature is above 90°F, you may experience hard starting and rough
idle following start-up even if the above recommendations are followed.
STARTING
The characteristics of E-85 fuel make it unsuitable for use when ambient temperatures fall below
0°F. In the range of 0°F to 32°F, you may experience an increase in the time it takes for your
engine to start, and a deterioration in driveability (sags and/or hesitation) until the engine is fully
warmed up.
CRUISING RANGE
Because E-85 fuel contains less energy per gallon than gasoline, you will experience an increase
in fuel consumption. You can expect your MPG and your driving range to decrease by about 30%
compared to gasoline operation.
REPLACEMENT PARTS
Many components in your Flexible Fuel Vehicle (FFV) are designed to be compatible with ethanol.
Always be sure that your vehicle is serviced with correct ethanol compatible parts.
CAUTION: Replacing fuel system components with non-ethanol compatible components can
damage your vehicle and may void the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Specifications
Fuel Filler Cap: Specifications
Pressure Vent Limit .............................................................................................................................
................................................ 1.5 psi (10 kPa) Vacuum Vent Limit ...................................................
........................................................................................................................ 1.8 in-Hg (6 kPa)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filler Cap > Component
Information > Specifications > Page 3720
Fuel Filler Cap: Description and Operation
Fig 3 Pressure Vacuum Filler Cap
A pressure-vacuum relief cap seals the fuel tank (Fig. 3). Tightening the cap on the fuel filler tube forms a seal between them.
The relief valves in the cap are a safety feature. They prevent possible excessive pressure or
vacuum in the tank. Excessive fuel tank pressure could be caused by a malfunction in the system or damage to the
vent lines.
The seal between the cap and filler tube breaks when the cap is removed. Removing the cap breaks the seal and relieves fuel tank pressure.
The filler cap is also a pressure/vacuum relief valve, which opens whenever pressure in the tank
gets either too low or too high.
Filler cap venting pressures: Pressure above 10.9 to 13.45 kPa (1.58 to 1.95 psi)
- Pressure below 0.97 and 2.0 kPa (0.14 and 0.29 psi)
Only filler caps with these specifications may be used as replacements.
WARNING: Remove filler cap to relieve tank pressure before removing or repairing fuel system
components.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > CNG Engine
Fuel Pressure Release: Service and Repair CNG Engine
Fuel Line Pressure Release Procedure
1. Close the fuel control valves on all cylinder(s) by turning the valves completely clockwise. 2.
Ensure the manual shut-oft valve is in the open position. The valve is open when the handle is
parallel with the fuel tubes. 3. Start or attempt to start the engine. If the engine runs, let it run until it
runs out of fuel. Attempt to start the engine by cranking for 6 seconds. 4. Pausing 10 seconds
between attempts, repeat step 3 two more times. 5. If the check valve or fuel fill receptacle is to be
serviced, slowly loosen the inlet side of the fuel fill tube fitting at the check valve until fuel has
purged.
WARNING: The fuel cylinders still contain high-pressure fuel.
Fuel Cylinder Pressure Release Procedure
1. Close the fuel control valves on the cylinders not being serviced by turning the valves completely
clockwise. 2. Ensure the manual shut-oft valve is in the open position. The valve is open when the
handle is parallel with the fuel tubes. 3. Start the engine and let it run until the fuel is depleted. 4.
Attempt to start the engine by cranking for 6 seconds. 5. Pausing 10 seconds between attempts,
repeat steps 3 and 4 two more times.
WARNING: The fuel cylinders that are not being serviced still contain high-pressure fuel.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Filter > Fuel Pressure
Release > System Information > Service and Repair > CNG Engine > Page 3726
Fuel Pressure Release: Service and Repair Gasoline Engine
Fig 10 Fuel Pressure Test Port
Fig 11 Releasing Fuel Pressure
WARNING: Release fuel system pressure before servicing fuel system components. Service
vehicles in well ventilated areas and avoid ignition sources. Never smoke while servicing the
vehicle.
1. Disconnect negative cable from battery. 2. Remove fuel filler cap. 3. Remove protective cap from
fuel pressure test port on fuel rail (Fig. 10). 4. Place open end of fuel pressure release hose, tool
number C-4799-1, into an approved gasoline container. Connect other end of hose C-4799-1 to
fuel pressure test port (Fig. 11). Fuel pressure will bleed off through the hose into the gasoline
container. Fuel gauge C-4799-B contains hose C-4799-1.
WARNING: Some fuel pressure may still be present in the system.
5. Replace pressure test port cap when finished doing pressure test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications
Fuel Injector: Electrical Specifications
Injector resistance should be between 3 and 6 ohms.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Electrical Specifications > Page 3731
Fuel Injector: Pressure, Vacuum and Temperature Specifications
Information not supplied by the manufacturer.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Specifications > Page 3732
Fuel Injector: Locations
Fuel Injectors
The fuel injectors are attached to the fuel rail which mounts to the lower intake manifold under the
air intake plenum.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Flex Fuel
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Flex Fuel > Page 3735
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3736
Fuel Injector: Description and Operation
Fig 2 Fuel Injector
Fig 3 Fuel Injector Location -- Typical
Fuel Injector - Cutaway View
The fuel injectors are 12 ohm electrical solenoids (Fig. 2). The injector contains a pintle that closes
off an orifice at the nozzle end. When electric current is supplied to the injector, the armature and
needle move a short distance against a spring, allowing fuel to flow out the orifice. Because the fuel
is under high pressure, a fine spray is developed in the shape of a hollow cone. The spraying
action atomizes the fuel, adding it to the air entering the combustion chamber. The injectors are
positioned in the intake manifold.
The injectors are positioned in the intake manifold with the nozzle ends directly above the intake
valve port (Fig. 3).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3737
Fuel Injector: Testing and Inspection
Fuel Injector Diagnosis
For fuel injector diagnosis, refer to the Fuel Injector Diagnosis charts.
For poor fuel economy diagnosis or engine miss, also consider Transmission problems as possible
causes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Injector > Component
Information > Diagrams > Page 3738
Fuel Injector: Service and Repair
Fig 55 Fuel Injector And Rail -- Typical
The fuel rail must be removed first.
REMOVAL
1. Disconnect injector wiring connector from injector. 2. Position fuel rail assembly so that the fuel
injectors are easily accessible (Fig. 55). 3. Rotate injector and pull injector out of fuel rail.
- The clip will stay on the injector.
4. Check injector 0-ring for damage.
- If 0-ring is damaged, it must be replaced.
- If injector is reused, a protective cap must be installed on the injector tip to prevent damage.
- Replace the injector clip if it is damaged.
5. Repeat for remaining injectors.
Fig 57 Servicing Fuel Injector -- Typical
INSTALLATION
1. Before installing an injector the rubber 0-ring must be lubricated with a drop of clean engine oil to
aid in installation. 2. Install injector clip by sliding open end into the top slot of the injector.
- The edge of the receiver cup will slide into the side slots of clip (Fig. 57).
3. Install injector top end into fuel rail receiver cap.
- Be careful not to damage 0-ring during installation (Fig. 57).
4. Repeat steps for remaining injectors. 5. Connect fuel injector wiring.
CAUTION: Fuel injectors are not interchangeable between engines.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Description and Operation
Fuel Line Coupler: Description and Operation
Fig 4 Plastic Quick Connect Fittings
Fuel tubes connect fuel system components with plastic quick-connect fuel fittings. The fitting
contains non-serviceable 0-ring seals (Fig. 4).
CAUTION: Quick-connect fittings are not serviced separately. Do not attempt to repair damaged
quick-connect fittings or fuel tubes. Replace the complete fuel tube quick-connect fitting assembly.
The quick-connect fitting consists of the 0-rings, retainer and casing (Fig. 4). When the fuel tube
enters the fitting, the retainer locks the shoulder of the nipple in place and the 0-rings seal the tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Quick Connect Fitting
Fuel Line Coupler: Service and Repair Quick Connect Fitting
Fig 12 Plastic Quick-connect Fitting/Fuel Tube Connection
When disconnecting a quick-connect fitting, the retainer will remain on the fuel tube nipple.
WARNING: Release fuel system pressure before disconnecting a quick-connect fittings. Refer to
the fuel pressure release procedure.
QUICK-CONNECT FITTINGS REMOVAL
1. Disconnect negative cable from battery. 2. Perform Fuel Pressure Release Procedure.
- Refer to the Fuel Pressure Release Procedure.
3. Squeeze retainer tabs together and pull fuel tube/quick-connect fitting assembly off of fuel tube
nipple. The retainer will remain on fuel tube.
CAUTION: Never install a quick-connect fitting without the retainer being either on the fuel tube or
already in the quick-connect fitting. In either case, ensure the retainer locks securely into the
quick-connect fitting by firmly pulling on fuel tube and fitting to ensure it is secured.
INSTALLATION
1. Using a clean lint free cloth, clean the fuel tube nipple and retainer. 2. Prior to connecting the
fitting to the fuel tube, coat the fuel tube nipple with clean 30 weight engine oil. 3. Push the
quick-connect fitting over the fuel tube until the retainer neats and a click is heard. 4. The
quick-connect fitting has windows in the sides of the casing. When the fitting completely attaches to
the fuel tube, the retainer locking ears
and the fuel tube shoulder are visible in the windows. If they are not visible, the retainer was not properly installed (Fig. 12).
- Do not rely upon the audible click to confirm a secure connection.
CAUTION: When using the ASD Fuel System Test, the Auto Shutdown (ASD) Relay remains
energized for either 7 minutes, until the test is stopped, or until the Ignition switch Is turned to the
OFF position.
5. Use the DRB scan tool ASD Fuel System Test to pressurize the fuel system. Check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Line Coupler > Component
Information > Service and Repair > Quick Connect Fitting > Page 3744
Fuel Line Coupler: Service and Repair Plastic Retaining Ring Type Fitting
Fig 13 Plastic Retainer Type Fitting
NOTE: This type of fitting can be identified by the use of a full-round plastic retainer ring (Fig. 13)
usually black in color.
WARNING: The fuel system is under a constant pressure (even with the engine off). Before
servicing any fuel system hoses, fittings or lines, the fuel system pressure must be released.
Perform Fuel Pressure Release procedure.
CAUTION: The interior components (O-rings, spacers, retainers) of this type of quick-connect fitting
are not serviced separately. Do not attempt to repair damaged fittings or fuel lines/tubes. If repair is
necessary, replace the complete fuel tube assembly.
DISCONNECTION/CONNECTION
1. Disconnect negative battery cable from the battery. 2. Perform the fuel pressure release
procedure. 3. Clean the fitting of any foreign material before disassembly. 4. To release the fuel
system component from the quick-connect fitting: firmly push the fitting towards the component
being serviced while firmly
pushing the plastic retaining ring into the fitting (Fig. 13) With the plastic ring depressed, pull the
fitting from the component. -
The plastic retainer ring must be pressed squarely into the fitting body. If this retainer is cocked
during removal, it may be difficult to disconnect fitting. Use an open-end wrench on the shoulder of
the plastic retainer ring to aid in disconnection.
5. After disconnection, the plastic retainer ring will remain with the quick-connect fitting connector
body. 6. Inspect fitting connector body, plastic retainer ring and fuel system component for
damage.
- Replace as necessary.
7. Prior to connecting the quick-connect fitting to component being serviced, check condition of
fitting and component.
- Clean the parts with a lint-free cloth.
- Lubricate them with clean engine oil.
8. Insert the quick-connect fitting into the component being serviced until a click is felt. 9. Verify a
locked condition by firmly pulling on fuel tube and fitting ( 15-30 lbs).
10. Connect negative battery cable to battery. 11. Start engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Compressed Natural Gas Engine
Fuel Control Valves
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Compressed Natural Gas Engine > Page 3749
Fuel Pressure Regulator: Locations Gasoline Engine
Fig 18 Fuel Pressure Regulator
The Fuel Pressure Regulator is part of the fuel pump module located in the fuel tank.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3750
Fuel Pressure Regulator: Description and Operation
The fuel system uses a nonadjustable pressure regulator that maintains fuel system pressure at
approximately 338 kPa (49 psi).
The fuel pressure regulator contains a diaphragm, calibrated spring and a fuel return valve. The
spring pushes down on the diaphragm and closes off the fuel return port. System fuel pressure
reflects the amount of fuel pressure required to open the return port.
The pressure regulator is a mechanical device that is NOT controlled by the PCM or engine
vacuum.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3751
Fuel Pressure Regulator: Adjustments
No adjustments available for the fuel system pressure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Regulator >
Component Information > Locations > Page 3752
Fuel Pressure Regulator: Service and Repair
Fig 18 Fuel Pressure Regulator
The fuel pressure regulator is part of the fuel pump module (Fig. 18). Remove the fuel pump
module from the fuel tank to access the fuel pressure regulator.
WARNING: Fuel system pressure must be released before servicing any fuel system component.
Perform the fuel system pressure release procedure.
REMOVAL
1. Spread tangs on pressure regulator retainer (Fig. 18). 2. Pry fuel pressure regulator out of
housing. 3. Ensure both upper and lower 0-rings were removed with regulator.
Fig 19 Fuel Pressure Regulator O-rings
INSTALLATION
1. Lightly lubricate the 0-rings with clean engine oil and place them into opening in pump module
(Fig. 19). 2. Push regulator into opening in pump module. 3. Fold tangs on regulator retainer over
tabs on housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Sensor/Switch >
Component Information > Locations > Page 3756
Fuel Low Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Locations > Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pressure Test Port >
Component Information > Locations > Compressed Natural Gas > Page 3761
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pressure >
Fuel Pressure Test Port > Component Information > Locations > Compressed Natural Gas > Page 3768
Fuel Pressure Test Port: Locations Gasoline
Fig 1 Intake Plenum Mounting Bolts
Center of fuel rail, (see "Fuel Pressure Test Port" Fig. 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3772
Fuel Pump Relay: Diagrams
Fuel Pump Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3773
Fuel Pump Relay: Testing and Inspection
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Pump > Fuel Pump Relay >
Component Information > Locations > Page 3774
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage
Technical Service Bulletin # 895 Date: 020101
Recall - Potential Fuel Rail Seal Leakage
January 2002
Dealer Service Instructions for
Safety Recall No. 895 -- Fuel Rail Seals
Models
1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or
"L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999).
IMPORTANT:
Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in
this recall.
IMPORTANT:
Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty
records, have been excluded from this recall.
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles
may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine
compartment fire.
Repair
External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube
joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3783
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3784
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required
Dealer Notification
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD895".
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by describing the reason on a postcard and mail
to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Customer Services Field Operations DaimlerChrysler Corporation
A. Inspect Fuel Rail
1. Raise hood.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3785
2. Inspect both of the fuel rail crossover tube joints (Figure 1)
3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
> If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube
joints, continue with Section B - Install Fuel Rail Seals.
B. Install Fuel Rail Seals
1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only),
remove the cover and set it aside.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3786
2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area
near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the
Scotch-Brite pad and then use compressed air to remove any remaining particles.
3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease
seal installation.
4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure
to coat the flat ends as well as the two beads.
IMPORTANT:
Drain any excess oil from the seals.
5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3).
NOTE:
Both of the seal halves are identical.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3787
6. Seat the seal halves around the joint and then while holding the two seals halves together, install
one of the provided clamps around the seal halves (Figure 4).
7. Tighten the clamp to 75 in-lbs (8.5 N.m).
8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3).
9. Seat the seal halves around the joint and then while holding the two seals halves together, install
the other clamp around the seal halves (Figure 4).
10. Tighten the clamp to 75 in-lbs (8.5 N.m).
11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the
cover must be modified as follows:
a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube
joint (Figure 5). Discard the clip.
b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the
mold line on the end of the cover (Figure 5).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3788
c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely.
12. No further action is necessary. Return the vehicle to the customer.
C. Replace Fuel Rail Assembly
NOTE:
Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the
inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail
replacement.
WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be
released before replacing the fuel rail.
1. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.
3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6).
WARNING:
Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and
around the pressure port to absorb fuel when pressure is released from the rail.
4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose
into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel
pressure.
5. Remove the hose from the fuel rail and reinstall the test port cap.
6. Remove the plastic intake manifold cover, if equipped.
7. Remove the air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3789
8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and
bracket (Figure 7).
9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors
(Figure 8).
10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3790
11. Disconnect the EGR tube from the intake manifold flange (Figure 10).
12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head.
13. Disconnect the MAP sensor electrical connector (Figure 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3791
14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12).
WARNING:
Wrap a shop towel around the hoses to catch any gasoline spillage.
15. Remove the Direct Ignition System (DIS) coil pack (Figure 13).
16. Remove the generator support bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3792
17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve
cover (Figure 14).
NOTE:
It is not necessary to completely remove the intake plenum from the vehicle.
18. Cover the intake manifold openings.
19. Remove the fuel rail attaching bolts (Figure 15).
20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack
electrical connectors (Figure 16).
21. Disconnect the fuel rail wiring harness from the main engine harness.
22. Remove the fuel rail assembly.
23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors
are easily accessible.
24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring
harness from the fuel rail.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3793
25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the
injector (Figure 17).
26. Remove the upper and lower injector 0-rings from the injectors.
27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil.
28. Install the new upper 0-rings (BLUE) on the top of the injectors.
CAUTION:
Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result.
29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil.
30. Install the new lower 0-rings (BLACK) on the bottom of the injectors.
31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot
of the injector.
32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully
seated. Use care so that the upper 0-ring is not damaged during installation.
33. Connect the injector wiring harness to the injectors.
34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail
assembly into place until all injectors are seated in their port.
35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22
N.m).
36. Connect the fuel injector wiring harness to the main engine wiring harness.
37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the
connector on until it clicks and then pull back to ensure a complete connection.
38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical
connectors (Figure 16).
39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake
plenum gasket surfaces.
40. Place the provided intake plenum gasket on the intake manifold.
41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum
bolts. Do NOT tighten.
42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3794
43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT
tighten.
44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely
install the mounting bolts. Do NOT tighten.
45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28
N.m).
46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m).
47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m).
48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10).
49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm).
50. Connect the MAP sensor electrical connector (Figure 11).
51. Connect the vacuum hoses to the intake plenum (Figure 9).
52. Connect the TPS and idle air control motor electrical connectors (Figure 8).
53. Connect the throttle body vacuum connectors (Figure 9).
54. Connect the throttle cable and speed control cable (if equipped) (Figure 7).
55. Install the intake manifold cover (if equipped).
56. Install the air inlet resonator.
57. Connect the negative battery cable.
58. Start the engine and check for any fuel leakage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > 895 > Jan > 02 > Recall - Potential Fuel Rail Seal
Leakage > Page 3795
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Recalls for Fuel Rail: > NHTSA00V268000 > Sep > 00 > Recall 00V268000:
Fuel Rail Cracks/Leaks
Fuel Rail: Recalls Recall 00V268000: Fuel Rail Cracks/Leaks
Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from
some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail.
Fuel leakage in the presence of an ignition source can result in a fire.
Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel
rail crossover tube, should the existing O-rings continue to degrade.
DaimlerChrysler has not yet provided NHTSA with an owner notification schedule.
However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should
be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to
an authorized dealer on an agreed upon service date and do not receive the free remedy within a
reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National
Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage
Technical Service Bulletin # 895 Date: 020101
Recall - Potential Fuel Rail Seal Leakage
January 2002
Dealer Service Instructions for
Safety Recall No. 895 -- Fuel Rail Seals
Models
1996-2000 (NS) Dodge Caravan/Grand Caravan; Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles equipped with a 3.3L or 3.8L gasoline engine ("R" or
"L" in the 8 VIN Position) through Engine Build Date - 102389 (August 26, 1999).
IMPORTANT:
Vehicles equipped with a 3.3L Flex Fuel engine ("G" in the 8th VIN position) are NOT involved in
this recall.
IMPORTANT:
Vehicles that already had a fuel rail with the proper O-rings installed, according to Warranty
records, have been excluded from this recall.
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject
After extended use, the fuel rail crossover tube 0-rings on about 1,136,000 of the above vehicles
may leak fuel. Fuel leakage in the presence of an ignition source can result in an engine
compartment fire.
Repair
External seals must be installed at both of the fuel rail crossover tube joints. If the crossover tube
joints are leaking or red rust exists in the area, the fuel rail assembly must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3805
Parts Information
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3806
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required
Dealer Notification
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced (or the current
dealer at the same street address) will receive a list of their involved vehicles. The vehicle list is
arranged in Vehicle Identification Number (VIN) sequence. Owners known to DaimlerChrysler are
also listed. The lists are for dealer reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD895".
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Vehicle Not Available
If a vehicle is not available for service, let us know by describing the reason on a postcard and mail
to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Customer Services Field Operations DaimlerChrysler Corporation
A. Inspect Fuel Rail
1. Raise hood.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3807
2. Inspect both of the fuel rail crossover tube joints (Figure 1)
3. > If there are signs of fuel leakage from either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
> If there are signs of RED rust near either of the fuel rail crossover tube joints, the fuel rail
assembly must be replaced. Continue with Section C - Replace Fuel Rail Assembly.
If there are NO indications of fuel leakage OR RED rust near either of the fuel rail crossover tube
joints, continue with Section B - Install Fuel Rail Seals.
B. Install Fuel Rail Seals
1. If the engine is equipped with an intake manifold cover (1996 and early-1997 3.8L engines only),
remove the cover and set it aside.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3808
2. Using the provided Scotch-Brite pad, clean any dirt or white oxide build-up from the fuel rail area
near the crossover tube joints (Figure 2). Clean both of the crossover tube joints with the
Scotch-Brite pad and then use compressed air to remove any remaining particles.
3. Install the two provided clamps around the crossover tube. Start the clamps for 1-2 turns to ease
seal installation.
4. Lightly lubricate the rubber material of the four fuel rail seal halves with clean engine oil. Be sure
to coat the flat ends as well as the two beads.
IMPORTANT:
Drain any excess oil from the seals.
5. Install two of the seal halves around the front fuel rail crossover tube joint (Figure 3).
NOTE:
Both of the seal halves are identical.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3809
6. Seat the seal halves around the joint and then while holding the two seals halves together, install
one of the provided clamps around the seal halves (Figure 4).
7. Tighten the clamp to 75 in-lbs (8.5 N.m).
8. Install the remaining two seal halves around the rear fuel rail crossover tube joint (Figure 3).
9. Seat the seal halves around the joint and then while holding the two seals halves together, install
the other clamp around the seal halves (Figure 4).
10. Tighten the clamp to 75 in-lbs (8.5 N.m).
11. If the engine was equipped with an intake manifold cover (1996 and early-1997 3.8L only), the
cover must be modified as follows:
a. Remove the spring clip from the cover that was attached to the fuel rail near the crossover tube
joint (Figure 5). Discard the clip.
b. Using a small cut-off wheel, saw or similar tool, remove the plastic cover material inside of the
mold line on the end of the cover (Figure 5).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3810
c. Reinstall the cover onto the intake manifold. Tighten the cover bolt securely.
12. No further action is necessary. Return the vehicle to the customer.
C. Replace Fuel Rail Assembly
NOTE:
Only fuel rails with fuel leakage or RED rust at the crossover tube joint, as determined by the
inspection in Section A, require replacement. Very few vehicles are expected to require fuel rail
replacement.
WARNING:
The fuel system is under constant fuel pressure even with the engine off. Fuel pressure must be
released before replacing the fuel rail.
1. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to record all radio settings before disconnecting the
battery and to reset all electronic memory (clock, radio settings, etc.) when you have completed the
service procedure.
2. Remove and reinstall the fuel tank filler cap to release the fuel tank pressure.
3. Remove the protective cap from the pressure test port on the fuel rail (Figure 6).
WARNING:
Do not allow fuel to spill onto the engine intake or exhaust manifolds. Place shop towels under and
around the pressure port to absorb fuel when pressure is released from the rail.
4. Obtain the hose from the fuel pressure gauge tool set # C-4799-1 Position one end of the hose
into an approved gasoline container, then attach the hose to the fuel rail test port to release the fuel
pressure.
5. Remove the hose from the fuel rail and reinstall the test port cap.
6. Remove the plastic intake manifold cover, if equipped.
7. Remove the air inlet resonator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3811
8. Remove the throttle cable and speed control cable (if equipped) from the throttle lever and
bracket (Figure 7).
9. Disconnect the idle air control motor and Throttle Position Sensor (TPS) electrical connectors
(Figure 8).
10. Disconnect the vacuum hoses from the throttle body and intake manifold (Figure 9).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3812
11. Disconnect the EGR tube from the intake manifold flange (Figure 10).
12. Disconnect the cylinder head-to- intake plenum strut from the cylinder head.
13. Disconnect the MAP sensor electrical connector (Figure 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3813
14. Disconnect the fuel hose quick connect fitting from the chassis fuel tube (Figure 12).
WARNING:
Wrap a shop towel around the hoses to catch any gasoline spillage.
15. Remove the Direct Ignition System (DIS) coil pack (Figure 13).
16. Remove the generator support bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3814
17. Remove the intake plenum mounting bolts and rotate the plenum back over the rear valve
cover (Figure 14).
NOTE:
It is not necessary to completely remove the intake plenum from the vehicle.
18. Cover the intake manifold openings.
19. Remove the fuel rail attaching bolts (Figure 15).
20. Disconnect the engine coolant temperature sensor and camshaft position sensor or coil pack
electrical connectors (Figure 16).
21. Disconnect the fuel rail wiring harness from the main engine harness.
22. Remove the fuel rail assembly.
23. Position the fuel rail on a clean bench or other suitable work surface so that the fuel injectors
are easily accessible.
24. Disconnect the injector wiring connectors from the fuel injectors and then remove the wiring
harness from the fuel rail.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3815
25. Rotate the injectors and then pull them out of the fuel rail. The injector clip will stay on the
injector (Figure 17).
26. Remove the upper and lower injector 0-rings from the injectors.
27. Lubricate the new upper 0-rings (BLUE) with a drop of clean engine oil.
28. Install the new upper 0-rings (BLUE) on the top of the injectors.
CAUTION:
Do NOT install the black 0-rings in the upper 0-ring position or fuel leakage may result.
29. Lubricate the new lower 0-rings (BLACK) with a drop of clean engine oil.
30. Install the new lower 0-rings (BLACK) on the bottom of the injectors.
31. Install the injector clips onto the injectors, if necessary, by sliding the open end into the top slot
of the injector.
32. Install the injectors into the new fuel rail (Figure 17). Make sure that the injector clips are fully
seated. Use care so that the upper 0-ring is not damaged during installation.
33. Connect the injector wiring harness to the injectors.
34. Put the tip of each injector into its port in the intake manifold and then gently push the fuel rail
assembly into place until all injectors are seated in their port.
35. In stall the fuel rail mounting bolts (Figure 15). Tighten the mounting bolts to 200 in-lbs (22
N.m).
36. Connect the fuel injector wiring harness to the main engine wiring harness.
37. Connect the fuel rail hose quick connect fitting to the chassis fuel tube (Figure 12). Push the
connector on until it clicks and then pull back to ensure a complete connection.
38. Connect the coolant temperature sensor and camshaft position sensor or coil pack electrical
connectors (Figure 16).
39. Remove the covering from the intake manifold openings. Clean the intake manifold and intake
plenum gasket surfaces.
40. Place the provided intake plenum gasket on the intake manifold.
41 Install the intake plenum onto the intake manifold (Figure 14) Loosely install the intake plenum
bolts. Do NOT tighten.
42. Install the generator bracket~ Loosely install the bracket bolts. Do NOT tighten.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3816
43. Install the cylinder head-to-intake plenum strut. Loosely install the strut mounting bolt. Do NOT
tighten.
44. Using the supplied gasket, connect the EGR tube to the intake plenum (Figure 10). Loosely
install the mounting bolts. Do NOT tighten.
45. Following the tightening sequence in Figure 14, tighten the intake plenum bolts to 250 in-lbs (28
N.m).
46. Tighten the generator bracket bolts to 40 ft-lbs (54 N.m).
47. Tighten the cylinder head-to-intake plenum strut bolt to 40 ft-lbs (54 N.m).
48. Tighten the EGR tube bolts to 200 in-lbs (22 N.m) (Figure 10).
49. Install the DIS coil pack (Figure 13). Tighten the bolts to 105 in-lbs (12 Nm).
50. Connect the MAP sensor electrical connector (Figure 11).
51. Connect the vacuum hoses to the intake plenum (Figure 9).
52. Connect the TPS and idle air control motor electrical connectors (Figure 8).
53. Connect the throttle body vacuum connectors (Figure 9).
54. Connect the throttle cable and speed control cable (if equipped) (Figure 7).
55. Install the intake manifold cover (if equipped).
56. Install the air inlet resonator.
57. Connect the negative battery cable.
58. Start the engine and check for any fuel leakage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > 895 > Jan > 02 > Recall Potential Fuel Rail Seal Leakage > Page 3817
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Fuel Rail: > NHTSA00V268000 > Sep > 00 >
Recall 00V268000: Fuel Rail Cracks/Leaks
Fuel Rail: All Technical Service Bulletins Recall 00V268000: Fuel Rail Cracks/Leaks
Mini vans built with 3.3L and 3.8L engines. The fuel injection delivery system can leak fuel from
some of the sealing O-rings or from hair line cracks in the thermoset fuel injection rail.
Fuel leakage in the presence of an ignition source can result in a fire.
Dealers will install a seal on the vehicle fuel rails to prevent external leakage of fuel from the fuel
rail crossover tube, should the existing O-rings continue to degrade.
DaimlerChrysler has not yet provided NHTSA with an owner notification schedule.
However, if a vehicle is leaking fuel from the O-rings or from a cracked fuel line, the vehicle should
be taken into a dealer to have this repaired as soon as possible. Owners who take their vehicles to
an authorized dealer on an agreed upon service date and do not receive the free remedy within a
reasonable time should contact DaimlerChrysler at 1-800-992-1997. Also contact the National
Highway Traffic Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT
(1-888-327-4236).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3822
Fuel Rail: Specifications
Fuel Rail Bolt .......................................................................................................................................
....................................................... 10 Nm (95 in lb)
Fuel Tube Holddown Screw ................................................................................................................
.......................................................... 4 Nm (35 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3823
Fuel Rail: Description and Operation
Fuel Rail
The fuel rail is a steel distribution pipe with mounting points for the fuel pressure regulator, 6 fuel
injectors, and injector wire harness. The fuel rail performs the dual functions of fuel supply to the
injection components, and providing the necessary brackets and fittings to mount the components
to the engine.
Fuel enters the fuel rail at the inlet tube, proceeds to the 6 fuel injectors and fuel pressure
regulator, and returns to the tank via the fuel return line.
The fuel rail is under constant fuel pressure and fuel pressure release is required prior to servicing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3824
Fuel Rail: Service and Repair
Fig 37 Air Inlet Resonator
Fig 44 Throttle Cable Attachment
WARNING: The fuel system is under a constant pressure of approximately 330 kPa (49 psi).
Perform fuel pressure release procedure before servicing the fuel rail or fuel injectors.
REMOVAL
1. Perform fuel system pressure release procedure. 2. Disconnect negative cable from battery. 3.
Remove intake manifold cover. 4. Remove air inlet resonator (Fig. 37). 5. Remove throttle cable
and speed control cable (if equipped) (Fig. 44) from throttle lever and bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3825
Fig 45 Electrical And Vacuum Connection To Throttle Body
6. Disconnect idle air control motor and Throttle Position Sensor (TPS) electrical connectors (Fig.
45).
Fig 46 Vacuum Connections
7. Remove vacuum hose harness from throttle body and intake manifold (Fig. 46).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3826
Fig 47 EGR Tube
8. Remove EGR tube to intake manifold flange bolts (Fig. 47). 9. Remove cylinder head to intake
plenum strut.
Fig 48 MAP Connector
10. Disconnect electrical connector from the MAP sensor (Fig. 48) 11. Remove engine mounted
ground strap.
Fig 49 Fuel Line Quick Disconnect
12. Remove the fuel hose quick connect fitting from the chassis tube (Fig. 49).
WARNING: Wrap a shop towel around hoses to catch any gasoline spillage.
Fig 50 Ignition Coils
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3827
13. Remove Direct Ignition System (DIS) coils (Fig. 50). 14. Remove generator bracket to intake
manifold bolt.
Fig 51 Intake Manifold Bolts
15. Remove intake mounting manifold bolts and rotate manifold back over rear valve cover (Fig.
51).
Fig 52 Fuel Rail Attaching Bolts
16. Cover intake manifold with suitable cover when servicing (Fig. 52). 17. Remove fuel tube
retainer bracket screw and fuel rail attaching bolts (Fig. 52). Spread the retainer bracket to allow
fuel tube removal clearance.
Fig 53 Camshaft Position Sensor Connector
18. Disconnect camshaft position sensor (Fig. 53) and engine coolant temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Rail > Component
Information > Technical Service Bulletins > Page 3828
Fig 54 Fuel Rail Removal
19. Remove fuel rail. Be careful not to damage the injector 0-rings upon removal from their ports
(Fig. 54).
INSTALLATION
1. Ensure injector holes are clean. Replace 0-rings if damaged. 2. Lubricate injector 0-rings with a
drop of clean engine oil to ease installation.
3. Put the tip of each injector into their ports.
- Push the assembly into place until the injectors are seated in the ports.
4. Install the fuel rail mounting bolts.
- Tighten bolts to 22 Nm (200 in lb) torque (Fig. 52).
5. Install fuel tube retaining bracket screw.
- Tighten screw to 4 Nm (35 in lb) torque.
6. Connect electrical connectors to camshaft position sensor and engine coolant temperature
sensor. 7. Remove covering on lower intake manifold and clean surface. 8. Place intake manifold
gasket on lower manifold.
- Put upper manifold into place and install bolts finger tight.
9. Install the generator bracket to intake manifold bolt and the cylinder head to intake manifold strut
bolts
- Do not tighten.
10. Following the tightening sequence in (Fig. 51), tighten intake manifold bolts to 28 Nm (250 in lb)
torque. 11. Tighten generator bracket to intake manifold bolt to 54 Nm (40 ft lb) torque. 12. Tighten
the cylinder head to intake manifold strut bolts to 54 Nm (40 ft lb) torque. 13. Connect ground strap
and MAP sensor electrical connector. 14. Connect vacuum harness to intake plenum. Connect
PCV system hoses. 15. Using a new gasket, connect the EGR tube to the intake manifold plenum.
- Tighten screws to 22 Nm (200 in lb) torque.
16. Connect electrical connectors to the TPS and idle air control motor. 17. Connect vacuum
harness to throttle body. 18. Install the Direct Ignition System (DIS) coils.
- Tighten fasteners to 12 Nm (105 in lb) torque.
19. Install fuel hose quick connector fitting to chassis tubes.
- Push the fitting onto the chassis tube until it clicks into place.
- Pull on the fitting to ensure complete insertion.
20. Install throttle cable and speed control cable (if equipped). 21. Install air inlet resonator. 22.
Connect negative cable to battery.
CAUTION: When using the ASD Fuel System Test, the ASD relay and fuel pump relay remain
energized for 7 minutes or until the test is stopped, or until the ignition switch is turned to the Oft
position.
23. With the ignition key in ON position, access the DRB scan tool ASD Fuel System Test to
pressurize the fuel system. Check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Return Line > Component
Information > Locations
Fuel Pump Module Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Supply Line > Component
Information > Locations
Fuel Pump Module Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Tank > Fuel Gauge Sender >
Component Information > Locations > Page 3839
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Fuel Temperature Sensor >
Component Information > Locations > Page 3843
Fuel Temperature Sensor Connector CNG
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Specifications
Idle Speed/Throttle Actuator - Electronic: Specifications
Idle Air Control Motor ...........................................................................................................................
....................................................... 2 Nm (18 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations
Idle Speed/Throttle Actuator - Electronic: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Locations > Component Locations > Page 3849
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions
Idle Speed/Throttle Actuator - Electronic: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3852
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3853
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3854
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3855
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3856
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3857
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3858
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3859
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3860
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3861
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3862
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3863
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3864
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3865
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3866
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3867
Idle Speed/Throttle Actuator - Electronic: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3868
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3869
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3870
Idle Air Control Moor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Diagram Information and Instructions > Page 3871
Idle Air Control Motor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3872
Idle Speed/Throttle Actuator - Electronic: Description and Operation
PURPOSE
Maintains optimum idle speed under varying engine loads.
Prevents deceleration die out.
OPERATION
Powertrain Control Module (PCM) calculates proper idle speed using information from throttle
position, vehicle speed, and coolant temperature sensors and brake, and neutral/safety switches.
PCM controls idle speed by actuating motor, varying air flow through bypass in throttle body.
Prevents decel die out by increasing air flow when throttle is closed suddenly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3873
Idle Speed/Throttle Actuator - Electronic: Testing and Inspection
NOTE: Idle Air Control (IAC) motor operation can be tested using a scan tool.
CAUTION: Proper safety precautions must be taken when testing the IAC motor.
- Set the parking brake and block the drive wheels
- Route all scan tool cables away from the cooling fans, drive belt, pulleys. and exhaust
components
- Provide proper ventilation while operating the engine
- Always return the engine idle speed to normal before disconnecting the exerciser tool.
- Follow scan tool manufacturer's instructions for testing the IAC motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Idle Speed/Throttle Actuator Electronic > Component Information > Diagrams > Page 3874
Idle Speed/Throttle Actuator - Electronic: Service and Repair
Fig 109 Servicing Idle Air Control Motor
NOTE: When servicing throttle body components, always reassemble components with new
0-rings and seals where applicable.
- Never use lubricants on 0-rings or seals, damage may result.
- If assembly of component is difficult, use water to aid assembly.
- Use care when removing hoses to prevent damage to hose or hose nipple.
REMOVAL
1. Disconnect negative cable from battory; 2. Remove electrical connector from idle air control
motor. 3. Remove idle air control motor mounting screws (Fig. 109). 4. Remove motor from throttle
body. Ensure the 0-ring is removed with the motor.
INSTALLATION
1. The new idle air control motor has a new 0-ring installed on it. If pintle measures more than 1
inch (25 mm) it must be retracted. Use the DRB
Idle Air Control Motor Open/Close Test to retract the pintle (battery must be connected.)
2. Carefully place idle air control motor into throttle body. 3. Install mounting screws. Tighten
screws to 2 Nm (17 in lb) torque. 4. Connect electrical connector to idle air control motor. 5.
Connect negative cable to battery
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Intake Air Plenum > Component
Information > Specifications
Intake Air Plenum: Specifications
Support Bracket Fastener ....................................................................................................................
...................................................... 54 Nm (40 ft. lbs.) Bolts ................................................................
.................................................................................................................................... 28 Nm (250
inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3883
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3884
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3885
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3886
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3887
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3888
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3889
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3890
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3891
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3892
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3893
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3894
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3895
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3896
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3897
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3898
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3899
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3900
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Diagram Information and
Instructions > Page 3901
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Diagrams > Page 3902
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Automatic Shut Down (ASD)
Relay <--> [Main Relay (Computer/Fuel System)] > Component Information > Testing and Inspection > Auto Shutdown
(ASD) Relay > Page 3905
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3910
Fuel Pump Relay: Diagrams
Fuel Pump Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3911
Fuel Pump Relay: Testing and Inspection
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Fuel Pump Relay > Component Information > Locations > Page 3912
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions
Automatic Shut Down (ASD) Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3918
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3919
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3920
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3921
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3922
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3923
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3924
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3925
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3926
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3927
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3928
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3929
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3930
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3931
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3932
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3933
Automatic Shut Down (ASD) Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3934
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3935
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Diagram Information and Instructions > Page 3936
Automatic Shut Down (ASD) Relay: Connector Views
Auto Shutdown Relay Connector
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Diagrams > Page 3937
Automatic Shut Down (ASD) Relay: Description and Operation
Fig 5 Power Distribution Center
PURPOSE
The ASD relay supplies battery voltage to the fuel injectors, electronic ignition coil and the heating
elements in the oxygen sensors.
OPERATION
The Powertrain Control Module (PCM) operates the Auto Shutdown (ASD) relay by switching the
ground path on and off.
The PCM controls the relay by switching the ground path for the solenoid side of the relay ON and
OFF. The PCM turns the ground path off when the ignition switch is in the OFF position unless the 02
Heater Monitor test is being run.
- When the ignition switch is in the ON or Crank position, the PCM monitors the crankshaft position
sensor and camshaft position sensor signals to determine engine speed and ignition timing (coil
dwell).
If the PCM does not receive the crankshaft position sensor and camshaft position sensor signals
when the ignition switch is in the Run position, it will de-energize the ASD relay.
The ASD relay is located in the Power Distribution Center (PDC). The PDC is located on the
driver's side inner fender well (Fig. 5). A label on the underside of the PDC cover identifies the
relays and fuses in the PDC.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Testing and Inspection > Auto Shutdown (ASD) Relay
Automatic Shut Down (ASD) Relay: Testing and Inspection Auto Shutdown (ASD) Relay
Fig. 29 ASD And Fuel Pump Relay Terminals
Fig 77 ASD And Fuel Pump Relay Terminals
Fig 78 ASD And Fuel Pump Relay Terminals
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Relays and Modules - Fuel
Delivery and Air Induction > Automatic Shut Down (ASD) Relay <--> [Main Relay (Computer/Fuel System)] > Component
Information > Testing and Inspection > Auto Shutdown (ASD) Relay > Page 3940
NOTE: Two styles of relay may have been used (Fig 77 or Fig 78). Both styles of relay can be
tested using this procedure.
The following description of operation and tests apply only to the Automatic Shutdown (ASD) and
fuel pump relays. The terminals on the bottom of each relay are numbered (Fig. 29).
OPERATION
Terminal 30: Is connected to battery voltage at all times for both the ASD relay and fuel pump
relay.
Terminal 85: The powertrain control module (PCM) grounds the coil side of the relay through
terminal number 85.
Terminal 86: Supplies voltage to the coil side of the relay. There is no wire terminal in the cavity.
OFF Position Terminal 87A: When PCM de-energizes the ASD and fuel pump relays, terminal
number 87A connects to terminal 30. This is the OFF position.
- Terminal 87A is the center terminal on the relay.
- There is no wire or terminal in the cavity.
In the OFF position voltage is not supplied to the rest of the circuit.
ON Position Terminal 87: When the PCM energizes the ASD and fuel pump relays, terminal 87
connects to terminal 30. This is the ON position.
- Terminal 87 supplies voltage to the rest of the circuit.
TEST
1. Remove relay from connector before testing. 2. With the relay removed from the vehicle, use an
ohmmeter to check the resistance between terminals 85 and 86 of the relay. The resistance should
be between 70 to 80 ohms.
3. Connect the ohmmeter between relay terminals 30 and 87A of the relay. The ohmmeter should
show continuity between terminals 30 and 87A. 4. Connect the ohmmeter between relay terminals
87 and 30 of the relay The ohmmeter should not show an open circuit at this time. 5. Connect one
end of a jumper wire (16 gauge or heavier) to relay terminal 85. Connect the other end of the
jumper wire to the ground side of a 12
volt power source.
6. Connect one end of another jumper wire (16 gauge or heavier) to the power side of the 12 volt
power source. DO NOT attach the other end of
the jumper wire to the relay at this time.
WARNING: Do not allow ohmmeter to contact terminals 85 or 86 during this test.
7. Attach the other end of the jumper wire to relay terminal 86. This activates the relay.
- The ohmmeter SHOULD show continuity between relay terminals 87 and 30.
- The ohmmeter SHOULD NOT show continuity between relay terminals 87A and 30.
8. Disconnect jumper wires.
Replace the relay if it did not pass the continuity and resistance tests. If the relay passed the tests,
it operates properly Check the remainder of the ASD and fuel pump relay circuits. Refer to
electrical diagrams.
NOTE: Other testing for this system or component is done at the system level. See: Computers
and Control Systems/Testing and Inspection/Diagnostic Trouble Code Tests and Associated
Procedures/Manufacturer Code Charts/Trouble Code (TC) Tests/DTC Test - CODE TO TC TEST
CHART (Checking for Trouble Codes)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Rollover Valve, Fuel Tank >
Component Information > Description and Operation
Rollover Valve: Description and Operation
This vehicle has 2 rollover valves on top of the fuel tank. These valves prevent prevent fuel flow
through the fuel tank vent valve hoses should the vehicle roll over.
The rollover valves on the fuel tank are not serviceable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Pressure Sensor/Switch > Component Information > Locations > Page 3948
Fuel Low Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations
Fuel Pressure Test Port, Fuel Pressure Sensor & Fuel Temperature Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Fuel Temperature Sensor > Component Information > Locations > Page 3952
Fuel Temperature Sensor Connector CNG
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Component Locations > Page
3957
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3958
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3959
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3960
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3961
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Sensors and Switches - Fuel
Delivery and Air Induction > Throttle Position Sensor > Component Information > Locations > Page 3962
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications
Throttle Body: Specifications
Throttle Body Bolts ..............................................................................................................................
..................................................... 26 Nm (225 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3966
Throttle Body: Description and Operation
Fig 43 Throttle Body
The throttle body is located on the left side of the intake manifold plenum.
The throttle body houses the throttle position sensor and the idle air control motor.
Air flow through the throttle body is controlled by a cable operated throttle blade located in the base
of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3967
Throttle Body: Testing and Inspection
Fig 97 Air Metering Fitting 6457
Fig 100 PCV Valve
1. Warm engine in Park or Neutral until the cooling fan has cycled on and off at least once. 2.
Ensure that all accessories are off. 3. Shut off engine. 4. Disconnect the PCV valve hose from the
intake manifold nipple (Fig. 100). 5. Cap the PCV valve nipple. 6. Install Air Metering Fitting 6457
(0.125 in orifice) to the intake manifold PCV nipple (Fig. 97). 7. Disconnect the idle purge line from
the throttle body nipple. 8. Cap the 3/16 inch nipple. 9. Connect the DRB scan tool to the data link
connector.
10. Restart the engine. Allow engine to idle until the cooling fan has cycled on and off at least one
180°F cycle. 11. Using the DRB scan tool, access the Minimum Airflow Idle Speed screen. 12. The
following will then occur:
- Idle air control motor will fully close.
- Idle spark advance will become fixed.
- DRB scan tool displays engine rpm.
13. If idle rpm is within the range shown in the Idle Specification chart, throttle body minimum
airflow is set correctly.
Idle Specifications Odometer
Reading Idle RPM
Below 1000 Miles 525-875 RPM
Above 1000 Miles 575-875 RPM
14. If idle rpm is not within specifications, shut off the engine and clean the throttle body as follows:
a. Remove the throttle body from engine.
WARNING: Clean throttle body in a well ventilated area. Wear rubber or butyl gloves, do not let
Mopar parts cleaner come in contact with eyes or skin. Avoid ingesting the cleaner. Wash
thoroughly after using cleaner.
b. While holding the throttle open, spray the entire throttle body bore and the manifold side of the
throttle plate with Mopar Parts Cleaner. Only
use Mopar Parts Cleaner to clean the throttle body.
c. Using a soft scuff pad, clean the top and bottom of throttle body bore and the edges and
manifold side of the throttle blade. The edges of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Specifications > Page 3968
throttle blade and portions of the throttle bore that are closest to the throttle blade when closed,
must be free of deposits.
d. Use compressed air to dry the throttle body. e. Inspect throttle body for foreign material. f.
Install throttle body on manifold.
g. Repeat steps 1 through 12. If the minimum air flow is still not within specifications, the problem is
not caused by the throttle body.
15. Shut off engine. 16. Remove Air Metering Fitting 6457 from the intake manifold PCV nipple.
Reinstall the PCV valve hose. 17. Uncap the throttle body idle purge nipple and connect the idle
purge line. 18. Remove DRB scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning
Throttle Body: Service and Repair Throttle Body Cleaning
WARNINGS: ^ Clean throttle body in a well ventilated area.
^ Wear proper eye protection. ^ Wear rubber or butyl gloves when using parts cleaner. ^ Avoid
ingesting cleaner. ^ Wash thoroughly after using cleaner.
PURPOSE
The throttle body is designed to have a gap between the throttle plate and the throttle bore, at
closed throttle (idle), for minimum air flow operation.
It is common for deposits to form in the throttle body and intake plenum. Deposits on the throttle
plate, and throttle bore, which reduce the minimum air flow gap, can cause idle and driveability
problems, (stalling at stops, rough or unstable idle), that may or may not set a Diagnostic Trouble
Code (DTC).
EXAMPLE: If the minimum air flow gap is reduced enough by deposits, and the throttle plate is
closed suddenly (deceleration), the Idle Air Control (IAC) motor cannot adjust fast enough to
compensate for the sudden lack of air, and the vehicle stalls.
INSPECTION
Visually inspect the throttle body for cracks, deformation or tampering. Replace throttle body if
there are any signs damage.
CLEANING PROCEDURE
1. Remove the throttle body. SEE COMPONENT REPLACEMENT AND REPAIR PROCEDURES.
CAUTION: Do not use harsh abrasives or tank solvent washing to clean the throttle body.
2. While holding the throttle open, spray the entire throttle body bore and throttle plate with suitable
cleaner. 3. Using a soft scuff pad, clean the throttle body bore and throttle blade (front, back and
edges). It is critical that the edges of the throttle blade, and
the portion of the throttle bore that are close to the throttle blade when it is closed, are free of
deposits.
4. Inspect the intake plenum, and clean, if deposits are visible. 5. Install throttle body, and perform
throttle body minimum airflow test. SEE DIAGNOSIS, TESTING AND INSPECTION
PROCEDURES
NOTES: If vehicle is difficult to start after cleaning throttle body, it may be necessary to reset
adaptive memory. SEE Powertrain Management/
Computers and Control Systems/Testing and Inspection/Procedures.
If minimum air flow idle speed is still not within specifications, after cleaning the throttle body, and
the throttle body shows no signs of physical damage, the problem is not caused by the throttle
body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning > Page 3971
Throttle Body: Service and Repair Throttle Body Replacement
Throttle Body Removal And Replacement
REMOVAL
1. Disconnect negative cable from battery cable. 2. Remove air inlet to throttle body hose clamp. 3.
Remove 2 screws and air inlet resonator.
Fig 102 Throttle Cable Attachment To Throttle Body
4. Remove throttle and the speed control (if equipped) cables from lever and bracket (Fig. 102).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Body > Component
Information > Service and Repair > Throttle Body Cleaning > Page 3972
Fig 105 Throttle Body Electrical And Vacuum Connections
5. Disconnect electrical connectors from the idle air control motor and throttle position sensor (TPS)
(Fig. 105). 6. Disconnect vacuum hoses from throttle body. 7. Remove throttle body to intake
manifold attaching nuts. 8. Remove throttle body and gasket.
INSTALLATION
1. Reverse procedure for installation. Tighten throttle body mounting nuts to 25 Nm (225 in lb)
torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Service and Repair
Throttle Cable/Linkage: Service and Repair
Fig 62 Throttle Cable To Throttle Body Attachment
CAUTION: When servicing the accelerator pedal, throttle cable or speed control cable, do not
damage or kink the core wire inside the cable sheathing.
REMOVAL
1. Working from the engine compartment, hold the throttle body throttle lever in the wide open
position. 2. Remove the throttle cable from the throttle body cam (Fig. 60), (Fig. 61) and (Fig. 62).
Fig 58 Accelerator Pedal And Throttle Cable -- Front View
3. From inside the vehicle, hold up the pedal and remove the cable retainer and throttle cable from
the upper end of the pedal shaft (Fig. 58).
Fig 59 Accelerator Pedal And Throttle Cable -- Rear View
4. Remove retainer clip from throttle cable and grommet at dash panel (Fig. 59). 5. From the
engine compartment, pull the throttle cable out of the dash panel grommet. The grommet should
remain in the dash panel. 6. Remove the throttle cable from throttle bracket by carefully
compressing both retaining ears simultaneously Then gently pull the throttle cable
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Cable/Linkage >
Component Information > Service and Repair > Page 3976
from throttle bracket.
INSTALLATION
1. From the engine compartment, push the housing end fitting into the dash panel grommet. 2.
Install the cable housing (throttle body end) into the cable mounting bracket on the engine. 3. From
inside the vehicle, hold up the pedal and install throttle cable and cable retainer in the upper end of
the pedal shaft. 4. At the dash panel, install the cable retainer clip between the end of the throttle
cable fitting and grommet (Fig. 59) 5. From the engine compartment, rotate the throttle lever wide
open and install the throttle cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Component Locations
Throttle Position Sensor: Component Locations
Throttle Body View With Idle Air Control Motor
Idle Air Control Motor And Throttle Position Sensor
Mounted on throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Component Locations > Page 3981
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3982
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3983
Throttle Position Sensor: Description and Operation
PURPOSE
PCM uses sensor input with other inputs to determine current operating conditions.
PCM adjusts air/fuel mixture (injector pulse width) and ignition timing.
OPERATION
The TPS connects to the throttle blade shaft The TPS is a variable resistor that provides the
Powertrain Control Module (PCM) with an input signal (voltage). The signal represents throttle blade position.
- As the position of the throttle blade changes, the resistance of the TPS changes.
The PCM supplies approximately 5 volts to the TPS. The TPS output voltage (input signal to the
powertrain control module) represents throttle blade position. The TPS output voltage to the PCM
varies from approximately 0.40 volt at minimum throttle opening (idle) to a maximum of 3.80 volts
at wide open throttle.
The TPS mounts to the side of the throttle body.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3984
Throttle Position Sensor: Testing and Inspection
To perform a complete test of the this sensor and its circuitry use a DRB or equivalent scan tool
and follow the appropriate procedures. To test the throttle position sensor only, refer to the
following:
The Throttle Position Sensor (TPS) can be tested with a digital voltmeter (DVM). The center
terminal of the sensor is the output terminal. One of the other terminals is a 5 volt supply and the
remaining terminal is ground.
Connect the DVM between the center and sensor ground terminal. Refer to Diagrams/Electrical for
correct pinout.
With the ignition switch in the ON position, check the output voltage at the center terminal wire of
the connector. Check the output voltage at idle and at Wide-Open-Throttle (WOT). At idle, TPS output voltage should be approximately O.38 volts- to 1.2 volts.
- At wide open throttle, TPS output voltage should be approximately 3.1 volts to 4.4 volts.
- The output voltage should gradually increase as the throttle plate moves slowly from idle to WOT.
NOTE: Check for spread terminals at the sensor and PCM connections before replacing the TPS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3985
Throttle Position Sensor: Adjustments
PROCEDURE
- The Throttle Position Sensor on this vehicle is fixed and adjustment is not required.
- If sensor output voltage is outside acceptable range, sensor should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Fuel Delivery and Air Induction > Throttle Position Sensor >
Component Information > Locations > Page 3986
Throttle Position Sensor: Service and Repair
Fig 108 Servicing Throttle Position Sensor
REMOVAL
1. Disconnect negative cable from battery. 2. Remove electrical connector from throttle position
sensor. 3. Remove throttle position sensor mounting screws. 4. Lift throttle position sensor off
throttle shaft (Fig. 108).
INSTALLATION
1. Install throttle position sensor on throttle shaft. Install mounting screws. Tighten screw to 2 Nm
(17 in lb) torque. 2. Connect electrical connector to throttle position sensor. 3. Connect negative
cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Firing Order > Component Information >
Specifications
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Number One Cylinder >
Component Information > Locations
Firing Order
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Timing > Timing Marks and Indicators >
System Information > Locations
Timing Marks and Indicators: Locations
This vehicle is not equipped with timing marks. However spark advance can be monitored using a
DRBII or equivalent scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Electrical Specifications > Page 4002
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Specifications > Page 4003
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4006
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4007
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4008
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4009
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4010
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4011
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4012
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4013
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4014
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4015
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4016
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4017
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4018
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4019
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4020
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4021
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4022
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4023
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4024
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4025
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 4026
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 4027
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 4028
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 4029
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Camshaft Position Sensor > Component
Information > Diagrams > Page 4030
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Specifications > Page 4034
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4037
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4038
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4039
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4040
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4041
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4042
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4043
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4044
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4045
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4046
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4047
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4048
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4049
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4050
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4051
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4052
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4053
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4054
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4055
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Diagram Information and Instructions > Page 4056
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 4057
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 4058
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 4059
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Crankshaft Position Sensor > Component
Information > Diagrams > Page 4060
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications
Ignition Cable: Specifications
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Specifications > Page 4064
Ignition Cable: Description and Operation
NOTE: Spark Plug cables are sometimes referred to as "secondary ignition wires".
PURPOSE
Transfer electrical current from the coil to the individual spark plugs at each cylinder.
Resistance type cables are used to suppress Radio Frequency Interference (RFI), from the ignition
system.
CONSTRUCTION
The spark plug cables and spark plug boots are made from high temperature silicone materials.
Heat Shields The spark plug boots utilize metal heat shields for thermal protection from the exhaust
manifold. The heat shields slide over the spark plug boots.
- The notches on the heat shields ensure the spark plug boot and shield twist together during spark
plug boot removal.
- They also identify proper heat shield installation on the boot for service.
- All spark plug cable leads are properly identified with cylinder numbers.
Reusing and Installing Heat Shields The spark plug heat shield can be reused if an ignition cable is replaced due to failure.
- Never reuse heat shield's that have heat shield anti-twist, side or spark plug attachment tabs bent
or missing.
- Ensure that the heat shield is properly attached to the spark plug to avoid RFI problems.
- The bottom of the spark plug heat shield must make contact with the spark plug hex.
Silicone Grease The inside of the spark plug boot is coated with a special high temperature silicone
grease for greater sealing and to minimize boot bonding to the spark plug insulator.
The convoluted tubing on the rear plug cables are made of a high temperature plastic material.
Service Life Under normal driving conditions, the spark plug cables have a recommended service
life of a 100,000 miles. The spark plugs have a recommended service life of 75,000 miles for
severe driving conditions.
CAUTION: The front ignition cables must not make contact with the oil dip stick tube and #5 cable
must not touch the coil mounting bolt to avoid abrasion/dielectric failures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview
Ignition Cable: Initial Inspection and Diagnostic Overview
INSPECTION
Check the high-tension cable connections for good contact at the ignition coil, distributor cap
towers and spark plugs. Terminals should be fully seated.
The terminals and covers should be in good condition. Terminals should fit tightly to the ignition
coil, distributor cap, and spark plugs. The cover (boot) of the cable should fit tight at the coil tower,
distributor tower or spark plug insulator.
NOTE: Loose cable connections can cause corrosion and increase resistance resulting in shorter
cable service life. To maintain proper sealing at terminal connections, do not disconnect cables.
This should only be done when testing.
Clean high tension cables with a cloth moistened with a nonflammable solvent and wipe dry. Check
for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 4067
Ignition Cable: Component Tests and General Diagnostics
Secondary Ignition Cable Insulation Test
CAUTION: Do not leave any one spark plug cable disconnected any longer than necessary during
testing. Excessive heat could damage the catalytic converter.
- Total test time must not exceed ten minutes.
CAUTION: To maintain proper sealing at the terminal connections, the connections should not be
broken unless testing indicates high resistance, an open circuit or other damage.
INSPECTION
Check connections at the coil pack and spark plugs. Terminals should be fully seated, and the nipples and spark plug covers should be in good
condition.
Covers should fit tightly on the coil pack and spark plug insulators.
Cable connections that are loose will corrode and increase the resistance and permit water to enter
the towers causing ignition malfunction.
INSULATION TEST
NOTE: When testing secondary cables for punctures and cracks with an oscilloscope follow the
equipment manufacturers instructions. If an oscilloscope is not available, secondary cables can be
tested as follows:
1. With the engine not running, connect one end of a test probe (i.e. a piece of wire with insulated
alligator clips on each end) to a good ground, other
end free for probing.
2. With engine running, move test probe along entire length of all cables (approximately 0 to 1/8
inch gap). If punctures or cracks are present there
will be a noticeable spark jump from the faulty area to the probe. Check the coil cable the same
way.
3. Replace ALL cracked, leaking or faulty cables.
Secondary Ignition Cable Resistance Test
Cable ...................................................................................................................................................
.............................................. Maximum Resistance
#1 .........................................................................................................................................................
............................................................ 18.5k ohms
#2 .........................................................................................................................................................
............................................................ 15.5k ohms
#3 .........................................................................................................................................................
............................................................ 20.4k ohms
#4 .........................................................................................................................................................
............................................................ 21.2k ohms
#5 .........................................................................................................................................................
............................................................ 27.7k ohms
#6 .........................................................................................................................................................
............................................................ 26.7k ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Service and Repair > Replacing Cables
Ignition Cable: Service and Repair Replacing Cables
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
sever injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly.
- Spark plug boot heat shields must be replaced if they are bent or damaged. It is extremely
important the shield is reinstalled correctly as shown. The bottom of the spark plug heat shield
must make contact with the spark plug socket hex.
- Never coat the inside of spark plug boots with silicone grease. Some types of silicone grease can
damage the ignition cable conductor.
SPARK PLUG CABLES #3 AND #5
Removal
1. Remove the resonator. 2. Grasp the spark plug boot/heat shield as close as possible to the
spark plug.
- Twist the boot slightly to break its seal with the plug and pull straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
3. Wipe spark plug insulator clean with a dry cloth before installation. 4. Remove the cable from the
retaining bracket.
- Make sure that they are also detached from the rear retaining clip mounted on the rear of the
intake manifold.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
3. Install the resonator.
SPARK PLUG CABLE #1
Removal
1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the four bolts from the
upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark plug
boot/shield assembly as close as possible to the spark plug. Twist the boot slightly to break its seal
with the plug and pull
straight back.
CAUTION: Do not use pliers, pull on the ignition cable, or pull the spark plug boot at an angle. This
could damage the spark plug insulator, terminal, or the cable insulation.
5. Wipe spark plug insulator clean with a dry cloth before installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Service and Repair > Replacing Cables > Page 4070
6. Remove the cable from the retaining bracket.
Installation
1. When installing the spark plug cables, make sure the coil and spark plug insulator and terminals
are fully seated.
- A click sound should be heard or terminal engagement is felt when the terminals are properly
attached.
2. Rotate Generator back into place. 3. Install upper Generator bracket with the four bolts. 4. Install
the accessory drive belt, refer to Cooling System.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Cable > Component Information >
Service and Repair > Replacing Cables > Page 4071
Ignition Cable: Service and Repair Cleaning Cables
Clean Spark Plug cables with a cloth moistened with a non-flammable solvent. Wipe the cables
dry. Check for brittle or cracked insulation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise
Ignition Coil: Customer Interest Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4080
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4081
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4082
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > Customer Interest for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4083
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise
Ignition Coil: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4089
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4090
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4091
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Ignition Coil: > 08-45-99 > Dec > 99 > Radio - Poor AM
Reception/Ignition Noise > Page 4092
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Electrical Specifications
Ignition Coil: Electrical Specifications
Coil Polarity
IGNITION COIL RESISTANCE @ 21°C-27°C (70°F-80°F)
Coil Manufacture Primary Resistance Secondary Resistance
Weastec 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
(Aluminum Towers)
Diamond Electric 0.45 TO 0.65 Ohms 7,000 to 15,800 Ohms
(Brass Towers)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Specifications > Electrical Specifications > Page 4095
Ignition Coil: Mechanical Specifications
Ignition Coil ..........................................................................................................................................
........................................... 12 Nm (105 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Component Locations
Ignition Coil: Component Locations
Ignition Coil And Coolant Temperature Sensor Location
Coil pack mounted on intake manifold, above thermostat housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Component Locations > Page 4098
Ignition Coil Electrical Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Page 4099
Fuel Injectors
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Page 4100
Coil Polarity
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Page 4101
Ignition Coil: Description and Operation
Fig 4 Coil Pack
WARNING: The direct ignition system generates approximately 40,000 volts. Personal injury could
result from contact with this system.
CONSTRUCTION
The ignition coil assembly consists of independent coils molded together (Fig. 4). The coil
assembly is mounted on the intake manifold. Spark plug cables route to each cylinder from the coil.
OPERATION
The coil fires two spark plugs every power stroke. One plug is the cylinder under compression.
- The other cylinder fires on the exhaust stroke.
The Powertrain Control Module (PCM) determines which of the coils to charge and fire at the
correct time.
Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5 and coil 3 fires cylinders 3 and 6.
The Auto Shutdown (ASD) relay provides battery voltage to the ignition coil. The PCM provides a
ground contact (circuit) for energizing the coil. When the PCM breaks the contact, the energy in the
coil primary transfers to the secondary causing the spark.
The PCM will de-energize the ASD relay if it does not receive the crankshaft position sensor and
camshaft position sensor inputs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Page 4102
Ignition Coil: Testing and Inspection
Fig 18 Ignition Coil Electrical Connector
Coil 1 fires cylinders 1 and 4, coil 2 fires cylinders 2 and 5, and coil 3 fires cylinders 3 and 6. Each
coil tower is labeled with the number of the corresponding cylinder.
1. Disconnect the electrical connector from the coil pack (Fig. 18).
Fig 19 Ignition Coil Terminal ID
2. Measure the primary resistance of each coil. At the coil, connect an ohmmeter between the B+
pin and the pin corresponding to the cylinders in
question (Fig 19). Resistance on the primary side of each coil should be 0.45 - 0.65 ohm at 21° to 27°C (70° to 80°F).
- A coil that has not been allowed to cool off, would result in inaccurate measurement results.
- Replace the coil if resistance is not within tolerance.
Fig 20 Checking Ignition Coil Secondary Resistance
3. Remove ignition cables from the secondary towers of the coil. Measure the secondary resistance
of the coil between the towers of each individual
coil (Fig. 20). Secondary resistance should be 7,000 to 15,800 ohms.
- Replace the coil if resistance is not within tolerance.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Ignition Coil > Component Information >
Locations > Page 4103
Ignition Coil: Service and Repair
Fig 2 Ignition Coil Removal
REMOVAL
1. Remove spark plug cables from coil (Fig. 2).
- Always twist the spark plug boots to break the seal with the plug and pull straight back on the
boot.
2. Remove ignition coil electrical connector. 3. Remove ignition coil mounting screws. 4. Remove
ignition coil.
INSTALLATION
1. Reverse the above procedure for installation.
- Tighten mounting screws to 12 Nm (105 in lb) torque.
2. Transfer spark plug cables to new coil pack.
- The coil pack towers and cables are numbered with the cylinder identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4107
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4108
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4109
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Knock Sensor > Component Information >
Locations > Page 4110
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications
Camshaft Position Sensor: Electrical Specifications
Slot Sensed .........................................................................................................................................
.............................................. approximately 5.0 Volts No Slot Sensed ..............................................
................................................................................................................................... approximately
0.3 Volts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Electrical Specifications > Page 4116
Camshaft Position Sensor: Mechanical Specifications
Camshaft Position sensor screw .........................................................................................................
....................................................... 14 Nm (125 in lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Specifications > Page 4117
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions
Camshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4120
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4121
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4122
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4123
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4124
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4125
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4126
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4127
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4128
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4129
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4130
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4131
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4132
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4133
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4134
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4135
Camshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4136
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4137
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4138
Camshaft Position Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4139
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 4140
Camshaft Position Sensor: Description and Operation
Fig 9 Camshaft Position Sensor
PURPOSE
- Sensor provides PCM with cylinder identification.
- PCM uses sensor input to determine fuel injection sequence and ignition timing.
Fig 10 Camshaft Sprocket
OPERATION
The sensor generates pulses as groups of notches on the camshaft sprocket pass underneath it
(Fig. 10).
The PCM keeps track of crankshaft rotation and identifies each cylinder by the pulses generated by
the notches on the camshaft sprocket. Four crankshaft pulses follow each group of camshaft pulses.
When the PCM receives 2 cam pulses followed by the long flat spot on the camshaft sprocket, it
knows that the crankshaft timing marks for cylinder 1 are next (on driveplate). When the PCM
receives one camshaft pulse after the long flat spot on the sprocket, cylinder number 2 crankshaft
timing marks are next. After 3 camshaft pulses, the PCM knows cylinder 4 crankshaft timing marks
follow. One camshaft pulse after the 3 pulses indicates cylinder 5. The 2 camshaft pulses after
cylinder 5 signals cylinder 6 (Fig. 10). The PCM can synchronize on cylinders 1 or 4.
When metal aligns with the sensor, voltage goes low (less than 0.3 volts). When a notch aligns with
the sensor, voltage switches high (5.0 volts). As a group of notches pass under the sensor, the
voltage switches from low (metal) to high (notch) then back to low. The number of notches
determine the amount of pulses. If available, an oscilloscope can display the square wave patterns
of each timing event.
Top Dead Center (TDC) does not occur when notches on the camshaft sprocket pass below the
cylinder. TDC occurs after the camshaft pulse (or pulses) and after the 4 crankshaft pulses
associated with the particular cylinder. The arrows and cylinder call outs on Figure 4 represent
which cylinder the flat spot and notches identify, they do not indicate TDC position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 4141
Fig 11 Camshaft Position Sensor
The camshaft position sensor is mounted in the front of the timing case cover (Fig. 11).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 4142
Camshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 4143
Camshaft Position Sensor: Service and Repair
Fig 5 Camshaft Position Sensor
REMOVAL
1. Disconnect camshaft position sensor electrical connector from the wiring harness connector (Fig.
5).
Fig 6 Camshaft Sensor Bolt Removal/Installation
2. Remove bolt holding sensor (Fig. 6).
- There is a hole in the bracket for tool access to the sensor bolt.
Fig 7 Camshaft Sensor Removal/Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Camshaft Position Sensor > Component Information > Diagrams > Page 4144
3. Rotate sensor away from block (Fig. 7). 4. Pull sensor up out of the chain case cover.
- Do not pull on the sensor lead.
- There is an 0-ring on the sensor case. The 0-ring may make removal difficult.
- A light tap to top of sensor prior to removal may reduce force needed for removal.
Fig 8 Camshaft Position Sensor And Spacer
NOTE: If the removed sensor is reinstalled, clean off the old spacer on the sensor face. A NEW
SPACER must be attached to the face before installation. Inspect 0-ring for damage, replace if
necessary. If the sensor is being replaced, confirm that the paper spacer is attached to the face
and 0- ring is positioned in groove of the new sensor (Fig. 8).
INSTALLATION
1. Apply a couple drops of clean engine oil to the 0-ring prior to installation. 2. Install sensor in the
chain case cover and rotate into position. 3. Push sensor down until contact is made with the
camshaft gear.
- While holding the sensor in this position, install and tighten the retaining bolt 14 Nm (125 in lb)
torque.
4. Connect camshaft position sensor electrical connector to harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications
Crankshaft Position Sensor: Specifications
Crankshaft Position sensor screw
..............................................................................................................................................................
12 Nm (105 in lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Specifications > Page 4148
Crankshaft Position Sensor: Locations
Crankshaft Position Sensor
The Crankshaft Position Sensor is mounted on the transaxle bellhousing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions
Crankshaft Position Sensor: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4151
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4152
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4153
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4154
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4155
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4156
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4157
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4158
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4159
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4160
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4161
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4162
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4163
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4164
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4165
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4166
Crankshaft Position Sensor: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4167
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4168
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4169
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Diagram Information and Instructions > Page 4170
Crankshaft Position Sensor Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 4171
Crankshaft Position Sensor: Description and Operation
Fig 6 Crankshaft Position Sensor
Fig 7 Timing Slots
Fig 8 Crankshaft Position Sensor
OPERATION
The crankshaft position sensor detects slots cut into the transmission driveplate extension (Fig. 7).
There are 3 sets of slots. Each set contains 4 slots, for a total of 12 slots.
Basic timing is set by the position of the last slot in each group. Once the Powertrain Control
Module (PCM) senses the last slot, it determines crankshaft position (which piston will next be at
TDC) from the camshaft position sensor input. The 4 pulses generated by the crankshaft position
sensor represent the 69°, 49°, 29°, and 9° BTDC marks. It may take the PCM one engine
revolution to determine crankshaft position.
The PCM uses crankshaft position reference to determine injector sequence, ignition timing and
the presence of misfire. Once the PCM determines crankshaft position, it begins energizing the
injectors in sequence.
The crankshaft sensor is located on the passengers side of the transmission housing, above the
differential housing (Fig. 8). The bottom of the sensor is positioned next to the drive plate.
CIRCUIT OPERATION
Circuit K7 supplies 8 volts from the Powertrain Control Module (PCM) to the crankshaft position
sensor. The K7 circuit originates at cavity 44 of
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 4172
the PCM connector.
Circuit K24 from the sensor provides an input signal to the PCM. The K24 circuit connects to cavity
32 of the PCM. On vehicles equipped with an electronically controlled automatic trans axle, circuit
K24 splices to the transmission control module.
The PCM provides ground for the crankshaft position sensor signal (circuit K24) through circuit K4.
Circuit K4 connects to cavity 43 of the PCM.
Helpful Information Circuit K7 also splices to supply 8 volts to the camshaft position sensor and
vehicle speed sensor.
Circuit K4 also splices to supply ground for the signals from the following: Upstream heated oxygen sensor
- Downstream heated oxygen sensor
- Camshaft position sensor
- Throttle position sensor
- Manifold absolute pressure sensor
- Engine coolant temperature sensor
- Knock sensor
- Intake air temperature sensor
- Vehicle speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 4173
Crankshaft Position Sensor: Testing and Inspection
The output voltage of a properly operating camshaft position sensor or crankshaft position sensor
switches from high (5.0 volts) to low (0.3 volts). By connecting a Mopar Diagnostic System (MDS)
and engine analyzer to the vehicle, technicians can view the square wave pattern.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Crankshaft Position Sensor > Component Information > Diagrams > Page 4174
Crankshaft Position Sensor: Service and Repair
Fig 4 Crankshaft Position Sensor Connector
Fig 5 Crankshaft Position Sensor And Spacer
REMOVAL
1. Raise and support vehicle. 2. Disconnect crankshaft position sensor electrical connector from
the wiring harness connector (Fig. 4). 3. Remove crankshaft position sensor retaining bolt. 4. Pull
crankshaft position sensor straight up out of the transaxle housing.
NOTE: If the removed sensor is to be reinstalled, clean off the old spacer on the sensor face. A
NEW SPACER must be attached to the sensor face before installation. If the sensor is being
replaced, confirm that the paper spacer is attached to the lace of the new sensor (Fig. 5).
INSTALLATION
1. Install sensor in transaxle and push sensor down until contact is made with the drive plate. While
holding the sensor in this position, and install and
tighten the retaining bolt to 11.9 Nm (105 in lb) torque.
2. Raise and support vehicle. 3. Connect crankshaft position sensor electrical connector to the
wiring harness connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest
for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest
for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page
4184
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be
Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be
Removed > Page 4190
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4191
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System >
Ignition Switch > Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 4192
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations
Knock Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4196
Map Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4197
Knock Sensor: Description and Operation
PURPOSE
When the knock sensor detects a knock in one of the cylinders, it sends an input signal to the
PCM. In response, the PCM retards ignition timing for all cylinders by a scheduled amount.
OPERATION
The knock sensor threads into the side of the cylinder block in front of the starter motor.
Knock sensors contain a piezoelectric material which constantly vibrates and sends an input
voltage (signal) to the PCM while the engine operates.
- As the intensity of the crystal's vibrations increase, the knock sensor output voltage also
increases.
CAUTION: Over or under tightening effects knock sensor performance -- possibly causing improper
spark control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4198
Knock Sensor: Testing and Inspection
The engine knock sensor is affected by a number of factors. A few of these are: Ignition Timing
- Cylinder Pressure
- Fuel Octane etc
The knock generates an AC voltage whose amplitude increases with increasing engine knock. The
knock sensor can be tested with a digital voltmeter.
The RMS voltage starts at about 20mVAC (at about 700 rpm) and increases to approximately
600mVAC (5,000 rpm).
If the output falls outside of this range a DTC will be set.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Sensors and Switches - Ignition System > Knock
Sensor > Component Information > Locations > Page 4199
Knock Sensor: Service and Repair
Fig 12 Knock Sensor
NOTE: The knock sensor threads into the side of the cylinder block in front of the starter (Fig. 12).
REMOVAL
1. Disconnect electrical connector from knock sensor. 2. Use a crow foot socket to remove the
knock sensor.
INSTALLATION
1. Install knock sensor. Tighten knock sensor to 10 Nm (7 ft lb) torque.
CAUTION: Over or under tightening effects knock sensor performance, possibly causing improper
spark control.
2. Attach electrical connector to knock sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications
Spark Plug: Specifications
Electrode Gap ......................................................................................................................................
.................................. 1.21-1.34 mm (0.048-0.053 in) Torque .............................................................
.............................................................................................................................................. 28 Nm
(20 ft lb)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4203
Spark Plug: Service Precautions
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4204
Spark Plug: Application and ID
Spark Plug ...........................................................................................................................................
............................................................... RN14PMP5 Thread .............................................................
................................................................................................................................................ (14mm)
3/4 in.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information >
Specifications > Page 4205
Spark Plug: Description and Operation
Fig 3 Platinum Plug Pads
NOTE: This engine uses platinum spark plugs. These spark plugs are double platinum and have a
recommended service life of 100,000 miles for normal driving conditions. The recommended
service life under severe conditions is 75,000 miles.
- A thin platinum pad is welded to each of the spark plug electrode ends as shown in (Fig 3).
- Use extreme care to prevent spark plug cross threading, mis-gapping and ceramic insulator
damage during plug removal and installation.
Resistor spark plugs are used in all engines and have resistance values of 6,000 to 20,000 ohms
when checked with at least a 1000 volt tester. Do not use an ohm meter to check the resistance of the spark plugs. This will give an inaccurate
reading.
Faulty or fouled spark plugs may perform well at idle speed, but frequently fail at higher engine
speeds. Faulty plugs can be identified in a number of ways: poor fuel economy, power loss,
decrease in engine speed, hard starting and, in general, poor engine performance.
Spark plugs also malfunction because of carbon fouling, excessive electrode air gap, or a broken
insulator.
CAUTION: Never attempt to file the electrodes or use a wire brush for cleaning platinum plugs.
This would damage the platinum pads which would shorten spark plug life.
Apply a very small amount of anti-seize compound to the threads when reinstalling the vehicle's
original spark plugs that have been determined good. -
Do not apply anti-seize compound to new spark plugs.
NOTE: Anti-seize compound is electrically conductive and can cause engine misfires if not applied
correctly. It is extremely important that the anti-seize compound does not make contact with the
spark plug electrodes or ceramic insulator.
Never force a gap gauge between the platinum electrodes or adjust the gap on platinum spark
plugs without reading the procedures.
Due to the engine packaging environment for this engine, extreme care should be used when
installing the spark plugs to avoid cross threading problems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator
Spark Plug: Testing and Inspection Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4208
Spark Plug: Testing and Inspection Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4209
Spark Plug: Testing and Inspection Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4210
Spark Plug: Testing and Inspection Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4211
Spark Plug: Testing and Inspection
Broken, Cracked or Chipped Insulator
Chipped Electrode Insulator
NOTE: Replace any spark plugs which have cracked broken or chipped insulators.
Symptoms: Insulator chipped or broken.
Possible Causes: Usually results from bending the center electrode while adjusting the spark plug electrode gap.
- Severe detonation also can separate the insulator from the center electrode.
- Sudden Rise In Tip Temperature.
- Severe Operating Conditions.
- Improper Gapping Of Plugs.
Brown to Gray/Tan Color - Normal Operating Condition
DESCRIPTION:
Brown to greyish-tan deposits and slight electrode wear.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Normal wear ^ Clean, regap, and install, if wear is not excessive
..............................................................................................................................................................
....................................................................................
Dry, Fluffy Black Deposits - Cold or Carbon Fouling
Normal Operation And Carbon Fouling
Symptoms: Dry, black deposits on the electrodes.
Possible Causes:
- On one or two plugs, may be caused by sticking valves or defective spark plug cables.
- On the entire set, may be caused by a clogged air cleaner.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4212
- Poor Ignition Output
NOTE: Cold fouling is normal when the vehicle is only operated for short periods. The spark plugs
do not reach a high enough operating temperature during short operating periods to burn fuel
completely.
Electrode Gap Bridging
Electrode Gap Bridging
Symptoms: Gap between the electrodes bridged by deposits.
Possible Causes: Loose deposits in the combustion chamber can accumulate on the spark plug electrodes during
continuous stop and-go driving. Then when the engine is suddenly subjected to a high torque load,
the deposits partially liquefy and bridge the gap between the electrodes, short circuiting the
electrodes.
NOTE: Spark plugs with electrode gap bridging can be cleaned using standard procedures.
Heavy Colored Deposits
DESCRIPTION:
Colored coatings heavily deposited on the portion of the plug projecting into the chamber and on
the side facing the intake valve.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Leaking Valve Seals (1 or 2 cylinders) - Check the valve seals. Replace if necessary. Clean, regap,
and reinstall
..............................................................................................................................................................
....................................................................................
Oil or Ash Encrusted
Oil Or Ash Encrusted
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4213
Symptoms: Electrodes encrusted with dry oil or ash.
Possible Causes: One or more plugs, evaluate the cause of oil entry into the combustion chamber.
Premature Electrode Wear - Preignition Damage
Preignition Damage
Symptoms: Center electrode dissolves first and the ground electrode dissolves somewhat later.
Insulators appear relatively deposit free.
Possible Causes: Excessive combustion chamber temperature.
- Incorrect spark plug heat range [1].
- Ignition timing is over advanced
- Other operating conditions are causing engine overheating.
[1] Spark plugs are designed to operate within a specific temperature range, called spark plug heat
range. Variations in thickness and length of the center electrode and porcelain insulator change
how fast the plug can dissipate heat and determine the plugs heat range.
Red, Brown, Yellow or White Deposits - Fuel Additives
Scavenger Deposits
Symptoms: Red, Brown, White or Yellow deposits.
Possible Causes: Normal condition caused by certain fuel additives which are designed to change the nature of
deposits and decrease spark plug misfire tendencies.
NOTE: Notice that accumulation on the ground electrode and shell area may be heavy but the
deposits are easily removed. Spark plugs with scavenger deposits can be considered normal in
condition and be cleaned using standard procedures.
Shiny Yellow Glaze
DESCRIPTION:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Broken, Cracked or Chipped Insulator > Page 4214
Shiny yellow glaze coating on the insulator.
POSSIBLE CAUSE ACTION
..............................................................................................................................................................
..................................................................................
Metal By-products Of Combustion - Avoid sudden acceleration with wide open throttle after long
periods of low speed driving.
..............................................................................................................................................................
....................................................................................
Spark Plug Inspection
- Remove the spark plugs and examine them for burned electrodes. Also check for fouled, cracked
or broken porcelain insulators. Keep plugs arranged in the order in which they were removed from
the engine. An isolated plug displaying an abnormal condition indicates that a problem exists in the
corresponding cylinder. Replace spark plugs at the intervals recommended in the Maintenance
Schedules.
- Spark plugs that have low mileage may be cleaned and reused if not otherwise defective. Refer to
the Spark Plug Condition of this section. After cleaning, file the center electrode flat with a small
point file or jewelers file. Adjust the gap between the electrodes to the specified dimension. The
spark plug gap is 0.89 mm (0.035 in).
- Always tighten spark plugs to the specified torque. Over tightening can cause distortion resulting
in a change in the spark plug gap.
Spark Plug Resistance Test
Resistance should be at least 6,000 to 20,000 ohms when checked with at least a 1000 volt tester.
Wet Oily Deposits
Symptoms: Electrodes coated with excessive wet fuel or oil.
Possible Causes: -
In older engines, wet fouling can be caused by worn rings or excessive cylinder wear.
- In new or recently overhauled engines, fouling may occur before normal oil control is achieved.
Break-in fouled spark plugs can be usually be cleaned and installed.
White or Gray - Burned or Blistered Insulator
Spark Plug Overheating
Symptoms: White or gray center electrode insulator that also appears blistered. The increase in
electrode gap will be considerably in excess of 0.001 in per 1000 miles of operation.
Possible Causes: Plug(s) with wrong heat range.
- Over advanced ignition timing.
- Detonation
- Cooling system malfunction
- Check for lean air-fuel mixture
- Check the torque value of the plugs to ensure good plug-engine seat contact
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Page 4215
Spark Plug: Adjustments
Setting Spark Plug Gap - Typical
Spark plugs that have low mileage may be cleaned and reused if not otherwise defective, carbon or
oil fouled.
CAUTION: The Platinum pads can be damaged during the measurement of checking the gap if
extreme care is not used.
- Use only a taper gap gauge
- Never force the gap gauge through the platinum pads. Only apply enough force until resistance is
felt.
- Never use a wire brush or spark plug cleaner machine to clean platinum spark plugs
- Use an OSHA approved air nozzle when drying gas fouled spark plugs.
If gap adjustment is required of platinum plug, bend only the ground electrode. DO NOT TOUCH
the platinum pads. Use only a proper gapping tool and check with a taper gap gauge.
CAUTION: Cleaning of the platinum plug may damage the platinum tip.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Page 4216
Spark Plug: Service and Repair
Fig 1 Spark Plug Boot Heat Shield Orientation
WARNING: The ignition cables should not be removed while the engine is hot. This could cause
server injury/burns and can cause damage to the ignition cables.
CAUTIONS:
- Use extreme care when removing and installing the spark plug cables.
- The spark plug boot heat shield needs to be installed correctly on the boot before being installed
on the engine (Fig. 1). If it is not installed correctly engine misfire would occur.
- Do not use pliers to pull the boot/heat shield assembly from the spark plugs. This will damage the
shield assembly
CAUTION: Note routing of secondary ignition cables before removing. Failure to route cables
properly may result in radio interference, ignition cross fire, or ignition short to ground.
NOTE: Keep plugs in order removed. A plug, that looks different from the rest, could be a problem
indicator.
SPARK PLUG #3 AND #5
REMOVAL 1. Remove the resonator. 2. Remove intake strut to cylinder head bolt at cylinder head.
3. Loosen bolt for intake strut at intake. 4. Swing strut away. 5. Grasp the spark plug boot/shield
assembly as close as possible to the spark plug. Twist the boot/ shield assembly slightly to break
the seal with the
plug and pull straight out, Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug insulator, terminal, heat shield or the insulation. Wipe
spark plug insulator clean with a dry cloth before installation.
6. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Install the cable into the retaining bracket.
- Make sure that they are also attached to the rear retaining clip mounted on the rear of the intake
manifold.
4. Swing strut back into place. 5. Install intake strut bolt to cylinder head at cylinder head. 6.
Tighten bolt to intake strut at intake. 7. Tighten bolt at cylinder head. 8. Install the resonator.
SPARK PLUG #1
REMOVAL 1. Remove the accessory drive belt, refer to Cooling System. 2. Remove the 4 bolts
from the upper half of the generator bracket. 3. Push the Generator rearward. 4. Grasp the spark
plug boot/shield assembly as close as possible to the spark plug. Twist the boot/ shield assembly
slightly to break its seal with the
plug and pull straight out. Do not use pliers, pull on the ignition cable, or pull the spark plug boot at
an angle. This could damage the spark plug
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Ignition System > Spark Plug > Component Information > Testing
and Inspection > Page 4217
insulator, terminal, or the insulation. Wipe spark plug insulator clean with a dry cloth before
installation.
5. Remove spark plug
INSTALLATION 1. Install spark plug and tighten to 28 Nm (20 ft lb). 2. When installing the spark
plug cables, make sure the coil or spark plug insulator and terminals are fully seated.
- A click sound should be heard or felt when the terminals are properly attached.
3. Pull Generator back into place. 4. Install upper Generator bracket with the 4 bolts. 5. Install the
accessory drive belt, refer to Cooling System.
OTHER PLUGS
REMOVAL 1. Spray compressed air around spark plug to prevent foreign material from entering
combustion chamber. 2. Remove spark plug wire by grasping boot and turning 1/2 turn while
pulling boot back in a steady motion. 3. Remove spark plug using socket with foam insert.
INSPECT FOR: Color of Deposits
- Excessive Deposits
- Electrode wear
- Cracked or Damaged Threads Or Insulator
- Worn or Bent Electrodes
- Damaged Gasket
INSTALLATION 1. Start plug in cylinder head by hand, to prevent cross threading.
CAUTION: Do not overtighten plugs, overtightening can distort plugs resulting in a changed gap.
2. Torque spark plugs to 20 ft-lbs (28 Nm). 3. Install secondary ignition cables on spark plugs, (be
sure connectors are pushed onto plug completely).
CAUTION: When replacing spark plugs because of a high speed miss condition; wide open throttle
operation should be avoided for approximately 80 km (50 miles) after installation of new plugs. this
will allow deposit shifting in the combustion chamber to take place gradually and avoid plug
destroying splash fouling shortly after the plug change.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 4224
Transmission Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder >
Page 4235
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder >
Page 4236
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed
Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed
Shifts/Shudder > Page 4242
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed
Shifts/Shudder > Page 4243
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 4246
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 4247
Control Module: Locations Power Distribution Center
Junction Block
Power Distribution Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 4248
Fuse Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4251
Control Module: Diagrams Control Module, A/T
Part 1 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4252
Part 2 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4253
Part 3 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4254
Part 4 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4255
Part 5 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4256
Part 6 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4257
Part 7 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4258
Part 8 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4259
Part 9 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 4260
Part 11 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4263
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4264
Control Module: Description and Operation TCM Inputs
General Information
GENERAL INFORMATION
The TCM receives input information and continuously processes this information through its logic
circuits to perform all of the control functions that it is designed to perform. However, some of these
control functions are internal to the TCM, while other control functions are performed when the
TCM provides some type of output signal to another control device or module. The following is a
description of TCM input sensors and output devices.
The TCM uses various inputs to determine when to upshift or downshift and when to engage or
disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous
feedback data for controlling shift quality. Without any input, the TCM has no way to determine the
state of the transaxle and cannot control its operation as designed.
Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other
components through the CCD Bus.
DIRECT (HARD-WIRED) TCM INPUTS
- Battery Feed
- Ignition RUN Signal
- Cranking Signal
- Throttle Position Sensor (TPS) Signal
- Engine speed signal (Distributor or DIS Crankshaft Position Sensor)
- Input Speed Sensor Signal
- Output Speed Sensor Signal
- Transmission Range Sensor**(Includes Transmission Temperature Sensor)
- Transmission Control Relay (Switched Battery)
- L/R Pressure Switch Signal
- 2-4 Pressure Switch Signal
- O/D Pressure Switch Signal
- Park/Neutral Position Switch*
- PRNDL Switch*
- Torque Reduction Request Line (TRD Link)
INDIRECT (CCD BUS) TCM INPUTS
- Target Idle Speed
- Engine Coolant Temperature (ECT) Sensor
- Battery Temperature Sensor*
- Brake Switch
- Engine and Body Identification
- Engine Speed (Verifies Direct Input Engine Speed Signal)
- Speed Control ON/OFF Switch
- Speed Control Set Speed
- A/C Clutch Engagement
- Vehicle Identification Number (VIN)
- Manifold Absolute Pressure (MAP) Sensor
- Torque Reduction Confirmation Response
- Relative Throttle Position (Beginning in 1998)
*: UP TO 1995 **: BEGINNING IN 1996
Battery and Ignition (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4265
BATTERY
A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced
and also fed to the contact side of the Transmission Control Relay. On vehicles with an original
TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the
adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or
road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated
per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in
memory; therefore, a quick learn or road test is not necessary.
IGNITION
When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START
(CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above
approximately 26 volts or below 8 volts, the TCM automatically powers down which results in
limp-in symptoms.
Throttle Position Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4266
The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift
quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5
volt supply and ground for the sensor. Target idle speed is compared against actual engine speed
to determine the learned TPS value for closed throttle idle. This is done to correct for differences in
system voltage and sensor tolerances.
If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by
substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier
vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts
that are vehicle speed dependent.
NOTE: Refer to TSB 18-13-94 if erratic shifting is evident.
Input Speed Sensors and Output Speed Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4267
The input speed sensor provides information to the TCM on how fast the torque converter turbine is
spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing.
The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input
clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is
induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this
information as input shaft rpm. This information is also compared to the output shaft speed and the
engine speed signal to determine the following:
- Planetary gears operating ratio
- Torque converter clutch slippage
- Torque converter element speed ratio
The output speed sensor is located on the same side of the transaxle case as the input speed
sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal
from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the
output speed sensor signal is received by the TCM, the signal is compared to the input speed
signal to determine gear ratio, detect clutch slippage, etc.
Pressure Switches (Hard-Wired)
The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack
Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits.
The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at
approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists
or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic
pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the
shift lever electrical signal is incorrect.
Transmission Temperature Sensor (Hard-Wired) (Beginning 1996)
The Transmission Temperature Sensor is used to monitor the temperature of the transmission
fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based
on the resistance value of the temperature sensor located in the Transmission Range Sensor
(TRS). The primary temperature inputs used by the TCM are the Transmission Temperature
Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be
running to get accurate temperature readings.
NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral
position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position
switch.
If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination
of inputs. The calculated fluid temperature is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4268
continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF.
On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the
vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a
value between the battery temperature and engine coolant temperature signals received from the
PCM over the CCD Bus.
The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The
temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS,
non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a
heat transfer equation that uses engine coolant temperature, battery/ambient temperature and
extended time off (if known) at start up.
Transmission Shift Scheduling
Once the engine is started, the TCM updates the transmission oil temperature based on the
following to determine an estimated oil temperature during vehicle operation (if a calculated oil
temperature is being used):
- Torque converter slip speed
- Vehicle speed
- Engine coolant temperature
- Battery/ambient temperature
Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal
operation. However, if a transmission oil cooler is added, a transmission is overfilled, a
transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the
calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be
inappropriate for the current conditions.
The key highlights of the various shift schedules are as follows:
Extreme Cold: Oil temperature at start up below -16° F.
- Goes to "Cold" schedule above - 12°F oil temperature
- Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent
shifts)
Cold: Oil temperature at start up above - 12 ° F and below 36°F
- Goes to "Warm" schedule above 40° F oil temperature
- Delayed 2-3 upshift (approximately 22 - 31 MPH)
- Delayed 3-4 upshift (45 - 53 MPH)
- Early 4-3 coastdown shift (approximately 30 MPH)
- Early 3-2 coastdown shift (approximately 17 MPH)
- High speed 4-2, 3-2, 2-1 kickdown shifts are prevented
- No EMCC
Warm: Oil temperature at start up above 36° F and below 80° F
- Goes to "Hot" schedule above 80°F oil temperature
- Normal operation (upshift, kick-downs and coast-downs)
- No EMCC
Hot: Oil temperature at start up above 80° F
- Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY)
- Normal operation (upshifts, kick-downs and coast-downs)
- Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH)
Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F
- Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH
97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F
- Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH)
- Delayed 3-4 upshift (41 - 48 MPH)
- 3rd gear FEMCC from 30 - 48 MPH
- 3rd gear PEMCC from 27 - 31 MPH
Super Overheat: 97 MY - Oil temperature above 240°F
- Goes back to "Overheat" below 240 ° F oil temperature
- All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
96 and prior MY - Oil temperature above 260°F
- Goes back to "Overheat" below 260 ° F oil temperature
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4269
- All "Overheat" shift schedule features apply
- 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
Causes for operation in the wrong temperature shift schedule:
Extreme Cold or Cold shift schedule at start up:
- Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only)
- Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only)
- Defective PCM (calculated oil temperature vehicles only)
- Defective sensor circuit (TRS equipped only)
Overheat or Super Overheat shift schedule after extended operation:
- Operation in city traffic or stop-and-go traffic
- Engine idle speed too high - Stuck AIS motor
- Aggressive driving in low gear
- Trailer towing in OD gear position (use "3" position if frequent shifting occurs)
- Cooling system failure causing engine to operate over 230° F
- Engine coolant temperature stays low too long - If engine coolant temperature drops below 150°
F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will
cause the transmission to overheat.
- A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC
disengaged will cause the transmission to overheat.
- Transmission fluid overfilled (TRS equipped only)
- Transmission cooler or cooler lines restricted (TRS equipped only)
- Defective sensor circuit (TRS equipped only)
Engine Speed (Hard-Wired and CCD Broadcast)
The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor,
as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is
required to provide immediate information for use by the TCM control logic. The CCD engine speed
data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid.
MAP Sensor (CCD Broadcast)
The MAP Sensor provides engine load input directly to the PCM, which determines engine torque
load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The
TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades.
Engine Idle Speed (Hard-Wired and CCD Broadcast)
The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle
speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual
engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle.
Brake Switch (CCD Broadcast)
The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque
converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control
when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4270
Battery/Ambient Temperature Sensor (CCD Broadcast)
The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD
broadcast information is used to control charging system, engine and transaxle operation. The
TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM
detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of
the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the
Battery Temperature signal along with engine coolant temperature to calculate the temperature.
Shift Lever Position (SLP)
The TCM identifies the position of the manual lever by comparing the current switch positions of
the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The
primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle
with the presence of an invalid or transition input code. The SLP logic function screens the input
codes from the switches and provides an SLP output signal to control actual gear selection.
Inputs include the codes indicated by the TRS current shift lever position, pressure switch
indications and speed ratio data from the input to most of the other functions in the TCM.
The identified position is stored in memory. The current switch position is determined by sensing
the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM
receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the
Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD
Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on
the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated.
CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with
sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is
a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse
but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed
data will not agree with the expected results for shift lever position = "OD." Therefore, it is important
to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes.
It is extremely important that accurate shift lever position data be available to the TCM. The
accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test,
performed on the DRB Scan Tool, passes without fail.
Torque Management Signal (CCD Broadcast)
With some engines, the TCM sends a direct input, torque management request signal to: the PCM.
This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque
management request signal is used in order to reduce the torque applied in the 2-4 and OD
clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel
injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine
during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a
very short time period. The PCM sends a confirmation of the request to the TCM over the CCD
Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually
be set.
The torque management signal is basically a 9-volt supply to the PCM. A torque management
request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is
called TRD link, which stands for "Torque Reduction Link."
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4271
PRNDL Switch (Hard-Wired)
NOTE: Used up to 1995 (Early 96 NS)
The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along
with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The
TCM uses this input to determine what gear range and shift pattern to use.
Park/Neutral Position Switch (Hard-Wired)
NOTE: Used up to 1995 and early 96 NS
The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and
Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position
Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both
switches must be closed to operate the back-up lamps.
Transmission Range Sensor (Hard-Wired)
The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission
Range Switch that are found on vehicles prior to the 1996
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4272
MY. This sensor allows for accurate transaxle gear position identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4273
Control Module: Description and Operation TCM Outputs
General Information
The TCM directly controls the following:
- Transmission Control Relay
- Solenoid pack
- Torque management requests to the PCM
Additionally, the TCM broadcasts the following information over the CCD Bus for use by other
vehicle control systems (Indirect Outputs):
- Communication with the DRB Scan Tool for diagnostics
- Shift lever position to the BCM
- Shift lever position to the shift lever display
- Transmission oil temperature to the PCM in order to activate the cooling fans
- Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus
- Limp - in Status
- Transmission Temperature
- In-gear position
NOTE: MIL request is from the PCM.
Transmission Control Relay
The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal
electronic circuits are all working properly. If the self-test results are good, then the TCM sends
battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts,
which then supply battery voltage to the TCM, the four solenoids and the three pressure switches
in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to
the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then
stored in memory. The Transmission Control Relay is located in various places depending on the
vehicle model.
Solenoid and Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4274
When the Transmission Control Relay contact points are closed, the solenoid assembly receives
electrical power. The TCM can then operate the solenoids, as determined by its programming. The
relay provides power to all four solenoids through a single wire. This means that all the solenoids
have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids,
however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is
needed.
The assembly is mounted to the outside of the transaxle case, under a sound shield protective
cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel
plate. There are also small solenoid valve filters used to protect the valves from contamination.
These filters are not replaceable. If the valve body and solenoid pack have been heavily
contaminated, the solenoid pack should be closely inspected to determine if it should be replaced.
The solenoid pack is not a serviceable unit.
The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control
Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to
four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the
solenoid/valves is that they directly control the application of a clutch. In other electronically
controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through
normal hydraulic valving. The solenoid assembly also contains pressure switches that feed
information to the TCM.
Vehicle Speed Signal
The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor
signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output
speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM.
The PCM receives this signal and converts it to a signal that can be used by the Body Control
Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent
over the CCD Bus.
Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4275
On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive
lockout function operated by a button on the instrument panel. The lockout feature makes driving
smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the
transaxle may shift in and out of overdrive, causing unnecessary shifting.
NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ
vehicles use a momentary contact switch.
Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and
provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to
normal operation and turn off the overdrive lockout lamp.
With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If
the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3
upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an
earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the
overdrive lockout switch or selection of the "3" position.
Electronic Pinion Factor
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRB Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration:
- If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when moving
- Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification
Use the following procedures to set the electronic pinion factor using the DRB Scan Tool:
- Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will
display the current tire size.
- If the tire size is incorrect, depress the Enter key and then select the correct size.
- Depress the Page Back key to exit the reset procedure.
Shifter/Ignition Interlock
The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the
automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The
interlock system locks the floor mounted shift lever into the PARK position whenever the ignition
switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the
shifter is unlocked and will move into any position. The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK
position.
Shift Position Indicator
The shifter position indicator is located in the instrument cluster. The shifter position indicator
outlines with a box the gear position the transaxle manual valve lever is in.
The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM
on the position of the transaxle manual valve lever. The TCM receives the switch signal and
processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the
CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster.
Autostick
Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When
the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using
before Autostick was activated. Moving the shifter to the left (towards the driver) causes a
downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument
cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while
in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift
schedule.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 4276
Automatic Overrides
Some shifts are executed automatically or prevented Automatic shifts will occur under the
illustrated conditions:
Additionally, under certain circumstances, the TCM may take over and override the autostick
features, for example, under the following conditions:
- Autostick switch input errors
- Error overspeed
- Engine overheating
- Transmission overheating Autostick shifts are not permitted under the illustrated conditions:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information > Page 4279
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations
Transmission Control System Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 4283
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 4284
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Transmission Range Sensor (TRS) Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 4290
Transmission Mode Switch: Description and Operation
PARK/NEUTRAL POSITION SWITCH INPUT (ATX)
Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to
the Powertrain Control Module (PCM) on gearshift position.
Circuit T41 connects to cavity 76 of the PCM.
TRANSMISSION RANGE SENSOR (TRS)
The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor
provides the Transmission Control Module (TCM) with information on shift lever position, contains
the transmission temperature sensor, and contains the switch for the back-up lamps.
Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the
NEUTRAL/OVERDRIVE or LOW position.
Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position.
Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE,
NEUTRAL, or LOW position.
Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL
position. This circuit is also the ground circuit for the coil side of the engine starter motor relay.
The TRS is case grounded to the transmission.
Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the
RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block.
When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1
circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive
(AWD) solenoids, if equipped.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 4291
Transmission Mode Switch: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
12. Remove TRS retaining screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 4292
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4301
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4302
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4303
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4309
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 4310
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4315
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4316
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4317
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 4323
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 4324
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4327
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 4328
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4329
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4330
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4331
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 4332
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 4341
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 4346
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 4347
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 4348
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control > Page 4354
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4359
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4360
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 4361
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 4362
Transmission Speed Sensor: Specifications
Input Speed Sensor .............................................................................................................................
...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor .....................................
........................................................................................................................................... 27 Nm (20
ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 4363
Transmission Speed Sensor: Locations
Transmission Control Components
Input / Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input (Turbine) Speed Sensor Connector > Page 4366
Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 4367
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4373
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4374
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4375
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4376
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4377
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4378
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4379
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4380
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4381
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4382
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4383
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4384
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4385
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4386
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4387
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4388
Transmission Temperature Sensor/Switch: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4389
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4390
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 4391
Transmission Control System (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor
Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 4394
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Description and Operation
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 4395
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 4396
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Circuit Operation
CIRCUIT OPERATION
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The
T54 circuit connects to cavity 54 of the TCM connector.
Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and
output speed sensor. This circuit connects to cavity 13 of the TCM connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Page 4397
Transmission Temperature Sensor/Switch: Testing and Inspection
Chrysler does not provide a procedure to test the transmission temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page
4406
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page
4407
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page
4408
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Recalls: > 771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page
4409
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall
Technical Service Bulletin # 18-05-99 Date: 990226
PCM - Sag/Hesitation/Stumble/Stall
NUMBER: 18-05-99
GROUP: Vehicle Performance
DATE: Feb. 26, 1999
SUBJECT: Sags/Hesitation/Stumble/Start & Stall, A/C Bump Improvements, Addition Of Leak
Detection Pump (LDP) Monitor Test
OVERVIEW: This bulletin involves selectively erasing and reprogramming the powertrain control
module (PCM) with new software (calibration changes).
MODELS: 1997 - 1998 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION: 1997/1998 3.0L ATX Powertrains
^ Sags/Hesitation/Stumble/Start & Stall after a cold start in ambient temperatures of -7° - 30° C (20°
- 86° F). This condition may persist for up to a minute into a drive cycle and is attributed to high
driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index fuel.
1997/1998 2.4/3.0/3.3/3.8L Powertrains
^ Provides further enhancements to the software originally released in Technical Service Bulletins
18-19-97 Rev A dated Oct. 17, 1997 and 18-20-98 dated Apr. 17, 1998 for "Bump" Feel during A/C
Compressor Engagement. See TSB 18-19-97A and/or 18-20-98 for further details regarding this
subject.
1997/1998 2.4/3.0/3.3/3.8L Powertrains Equipped With Leak Detection Pump (1998 California
Emission (Sales Code NAE) only included LDP)
^ Addition of LDP Monitor Test. This test makes the DRB III(R) capable of running the LDP
monitor. This will allow technicians to verify LDP repairs easily.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool
(DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission
systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record
them on the repair order and repair as necessary before proceeding further with this bulletin. If no
DTC's are present and the customer has described the above symptoms, perform the Repair
Procedure.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE
LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED
CONTROLLERS AS NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 MDS1 or MDS2
NOTE:
THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF
USING THE MDSl AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR
HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2
AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall
> Page 4415
Labor Operation No: 08-19-42-98 0.5 Hrs.
FAILURE CODE: FM - Flash Module
MDS1 Procedure
1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
power them up.
2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R)
MAIN MENU SCREEN.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then
press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE
MDS1 & DRB III(R) on the MDS, then press NEXT MENU.
7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain
the current part number of the PCM.
8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s).
Press NEXT MENU to begin programming.
NOTE:
A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART
NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE
MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT
FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE
LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL
REQUIRE FURTHER INVESTIGATION.
9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
MDS2 Procedures
1. Log onto the MDS2 system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall
> Page 4416
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information
Technical Service Bulletin # 25-02-98 Date: 981023
I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information
MODELS:
1996 - 1999 (AB) Ram Van/Wagon
1996 - 1999 (AN) Dakota
1996 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1996 - 1999 (FJ) Avenger/Sebring/Talon
1996 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper Roadster/Coupe
1997 - 1999 (TJ) Wrangler
1999 (WJ) Grand Cherokee
1996 - 1999 (XJ) Cherokee
1996 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE
ENGINES.
DISCUSSION:
Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a
prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their
self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or
more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their
tests.
It is important to understand that the MIL will not be illuminated because OBD Readiness reads
"NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions
system occurs. It is possible to have MIL illumination for a detected failure while at the same time
having a "NO" for an OBO Readiness monitor.
NOTE:
MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER
DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS
BULLETIN.
OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM
replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items
occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for
OBD Readiness.
Some customers may be directed back to their dealers for assistance when an I/M test station has
not allowed an I/M test due to Readiness status. The following procedures will help technicians
efficiently run the Readiness tests so an owner can have their I/M test completed.
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7000/7001 J1962Cable
1 CH7OlO J1962 MMC Cable
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information > Page 4421
TIME ALLOWANCE:
Labor Operation No: 25-01-01-91 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
This bulletin involves operating the vehicle under specific parameters to run or complete the OBD
monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions
application. In addition, the parameters to run each monitor will vary.
Preliminary Checks
1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate
as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit.
2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year
diagnostics, engine, DTC's and related functions, read DTC's.
3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the
engine running.
NOTE:
EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS
FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE
ATTEMPTING TO RUN THE MONITORS.
OBD "CARB" Readiness Check
1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status.
2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO"
tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned
to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read
"YES".
NOTE:
THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES
APPLICABLE FOR THE VEHICLE BEING WORKED ON.
The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to
run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The
pre-test/monitor test screen lists all the preliminary parameters that must be met along with the
running parameters for that specific monitor to run. An example of one screen is shown in Figure 1.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information > Page 4422
NOTE:
1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN.
PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE
MONITORS RUN WILL BE SIMILAR.
The following explains how to interpret each section of the screen:
PRE-TEST REQUIREMENTS
The pre-test requirements include all the operating parameters that must be met before the actual
test can run. The vehicle must be operated until each item within the pre-test section are fulfilled.
LOW VALUE/HIGH VALUE/BAR GRAPH
The low value/high value provides the minimum and maximum operating conditions for each item
(ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when
the lowest value required for each item is met. This provides a visual indication that the parameters
are being met. The vehicle should be driven until most of each pre-test bar graph is filled.
MONITOR REQUIREMENTS
Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in
the monitor requirements section for the monitors to begin running. As the monitor begins to run,
the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle
operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician
must determine if the pre-test requirements or the monitor requirements have fallen outside the
window for the test and the vehicle must be driven accordingly for the test to restart. When the
monitor completes its test, the DRB III(R) will beep 3 consecutive times.
NOTE:
THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE
PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR
SCREEN FOR THIS MONITOR.
MONITOR RUN PROCESS
The following will provide the most efficient order along with tips to help run through the monitor
tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear
Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum
available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The
only monitors that will require attention are those that read "NO" under the OBD "CARB"
Readiness Status screen.
Front Wheel Drive
1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or out depending on conditions). The ambient (outside) temperature must be
between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining requirements.
2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the
requirements.
3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test
screen for this test to complete.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left
in drive for the test to run. If all parameters are met and the test still will not run, place your foot on
the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells
to update.
6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded.
This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No
Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater
monitor status. It should have switched to "YES". All other monitors should be completed before
running this test.
Rear Wheel Drive
1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either
indoors or outdoors depending on conditions). The ambient (outside) temperature must be between
18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 25-02-98 > Oct > 98 > I/M Testing - OBDII CARB
Readiness Monitor Information > Page 4423
requirements.
2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must
be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F)
of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test
screen on the DRB III(R) to determine the remaining requirements.
3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet
the requirements.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transmission vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be
left in drive for the test to run. If all parameters are met and the test will still not run, place your foot
on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF
cells to update.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay
Actuation
PROM - Programmable Read Only Memory: Customer Interest PCM - Improper Cooling Fan Relay
Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > Customer Interest: > 18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay
Actuation > Page 4428
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery
Technical Service Bulletin # 18-037-05 Date: 051020
Engine Controls - Flash Programming Failure Recovery
NUMBER: 18-037-05
GROUP: Vehicle Performance
DATE: October 20, 2005
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Flash Programming Failure Recovery Using DRBIII(R)
OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and
information on recovery procedures for failed flash attempts.
MODELS:
1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2003 (AB) Ramvan/Wagon
1992 - 1994 (AJ) Lebaron Coupe/Convertible
1995 - 2004 (AN) Dakota
1992 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 2002 (BRIBE) Ram Pickup
2004 - 2006 (CS) Pacifica
1998 - 2003 (DN) Durango
2002 - 2005 (DR/DH/D1) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1996 - 2000 (CS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2005 (KJ) Liberty/Cherokee (International Markets)
1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2005 (PL) Neon
2002 (PG) PT Cruiser (International Markets)
1997 - 2002 (PR) Prowler
2001 - 2005 (PT) PT Cruiser
2001 - 2006 (RG) Chrysler Voyager (International Markets)
2001 - 2006 (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4434
1995 - 2002 (SR) Viper
2001 - 2005 (ST) Sebring Coupe/Stratus Coupe
1997 - 2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets)
1999 - 2004 (WJ) Grand Cherokee
1997 - 2001 (XJ) Cherokee
1993 - 1995 (YJ) Wrangler
2003 - 2006 (ZB) Viper
1995 - 1998 (ZG) Grand Cherokee (International Markets)
2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
NOTE:
Many of the reasons a flash reprogramming procedure may not complete are documented in this
service bulletin, but if you are constantly having issues performing the flash reprogramming
procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to
SPX/Miller Special Tools for service.
Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment
may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL
PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an
interruption or failure while reprogramming, are recoverable; a recoverable module is not covered
under the provisions of the warranty.
This service bulletin covers items that may cause this condition, a process to restart the flash
procedure, and miscellaneous information that will help prevent needless replacement of control
modules.
GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or
RECALL.
Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often
other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE
REQUIRED as part of completing the Service Bulletin/Recall.
When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there
are other legal requirements with labeling issues that are included in those service bulletins.
Other non-emission related modules, such as instrument clusters and Body Control Modules
(BCMs) do not require labels.
FLASH REPROGRAMMING SEQUENCE OF EVENTS
The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer.
Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere
with the process. This document seeks to provide information to minimize problems associated
with vehicle control module flash reprogramming. The description that follows is for most PCMs
and some TCMs. Other modules use different initiation procedures.
The process starts by selecting an update from the TechCONNECT Client or ISIS and then
"loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the
DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update
loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done
using part number supersedence. This verification occurs only if an update is required, available
(on the TechCONNECT Client or ISIS) and has been selected for programming.
^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module
mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming
session.
^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe
Memory" location within the module. This memory location is not affected by flash memory erasure
and reprogramming, which are to follow.
^ Once the part number is safely stored, the flash memory in the control module is erased. From
this point forward any interruption in the flash process,
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4435
will result in a Non-Responsive module (NR). A NR module is a module that is either partially
erased or partially programmed.
^ After erasure, the actual reprogramming procedure starts, and the update software is
programmed into the flash memory within the module.
^ When reprogramming is completed, the flash memory is verified through an internal process in
the DRBIII(R) using a "Check Sum". This value is compared against another value that represents
what should be in memory and when matched, verifies successful reprogramming.
^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The
module exits the "Boot Strap" mode when the switch is turned off.
^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The
DRBIII(R) then reads the new part number in flash memory (along with a new computer program
the new part number is placed into the module's memory). If the new part number matches the
expected part number, the flash reprogramming session has completed successfully.
SOFTWARE VERSIONS MUST BE CURRENT
Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you
have the most current DRBIII(R) software installed.
To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the
TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version.
Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The
installed DRBIII(R) software version can generally be found at the bottom center of most screens.
Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and
comparing it to what is available from a current TechCONNECT Client as described above.
If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the
TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new
support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is
why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions
installed.
DO NOT PASS on the option for updating to a "minor" revision!
Major updates require the DRBIII(R) to be updated prior to allowing any flash programming.
DRBIII(R) CABLES
A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft.
Cable, DRBIII(R) to OBDII (J1962) DLC Connector.
CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used
for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct
cable has a RED connector, which plugs into the DRBIII(R).
The cable modification enhances the DRBIII(R) communication capabilities when dealing with the
flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC
connector configurations.
The new cable is required for ALL flash reprogramming sessions, and can be used wherever the
previous CH700017001 cables were used.
While not recommended for flash reprogramming usage, if you require a longer cable, there is also
a 12-foot cable released under pin CH7001A
The production of the previous CH700017001 cables has ceased. All orders placed will be
superseded to part number CH7000A/CH7001A.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4436
NOTE:
Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are
damaged or do not lock securely, and all mating connections including checking for corrosion on
the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash
reprogramming.
Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming
sessions.
The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O
cable (Pre-OBDII MMC vehicles will use the CH7005 cable).
TechCONNECT CABLE (GPIB)
Replace any suspect GPIB cable.
The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R).
This cable is used by the TechCONNECT Client for vehicle part number reads and to send update
files to the DRBIII(R).
Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If
this cable becomes disconnected during a flash session, you may have to reload the update file
that you selected on the TechCONNECT Client.
TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT
APPLICATION.
1. Turn-on the power to the DRBIII(R) unit.
2. Select option 2 "Connect to TechCONNECT" and press Enter.
3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number
CH7035B) to the DRBIII(R) unit.
4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is
properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol
converter, (part number CHGPIB-B).
5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the
rear panel of the client CPU.
6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will
detect the device and install software for it. Please wait for 25-30 seconds to complete the
installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4437
ISIS NULL MODEM CABLE
Replace any suspect null modem cables.
International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem
cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for
loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes
disconnected during a flash download session, you will have to reload the update file or files.
GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS
Consider ALL cables to be wear items.
Many successful dealers have dedicated cables devoted to "Flash ONLY".
Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available.
Inspect vehicle diagnostic connectors for potential problems that might cause communication
interruptions.
There are now clip repair kits available through teamPSE to replace the retaining clips for two of
these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above
25 lbs. of axial force. Kits are described in the table.
It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general
damage beyond the retaining clips.
ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4438
These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT)
was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded
from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users
should closely follow the instructions that come with the tool. If the tool has not been initialized,
there is a known condition where it may take up to 5 or more attempts for it to fully initialize and
become functional.
NOTE:
Once it has successfully flashed, it is initialized and no further action is required.
PREPARING TO FLASH
It is highly recommended that a sign, or other process, be used that notifies other users that a
FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash
reprogramming sessions at critical junctures can render a module inoperative. Another user may
not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do
something on the vehicle that could interrupt the flash process.
Before starting the flash session, read, record and erase all DTCs found on the vehicle.
Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the
DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the
same time. Then press "F4").
Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an
area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it
rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have
been known to be swept off vehicle windshields by accident when a user bumps the wiper switch).
Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to
make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash
reprogramming errors may occur.
VEHICLE BATTERY VOLTAGE
The flash programming procedure puts a load on the electrical system that may last from five to
twenty minutes depending on the particular flash reprogramming update. Connect a battery
charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a
timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to
prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by
voltage fluctuations.
Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to
ensure adequate and stable system voltages on the module being flash reprogrammed.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Connected/Disconnected Flash Mode Using TechCONNECT
CONNECTED MODE FLASHING USING TechCONNECT
NOTE:
Capable but not recommended.
In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle
throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the
GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most
vehicles).
This mode is useful when the TechCONNECT Client is next to the vehicle being flashed.
Another advantage of this mode is that you are able to determine all available flash updates for the
vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button.
Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client
while a flash update is in-progress.
The reprogramming procedure of this mode is initiated by selecting the controller option and
clicking "Download/Update" button on the TechCONNECT client.
DISCONNECTED FLASH MODE
NOTE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4439
This is the preferred method.
This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client.
This is a popular mode for flashing in a remote area of the service garage or in a back lot.
Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s).
To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and
the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will
be used to communicate with the TechCONNECT Client (for update file downloading) while the
CH7025 cable is used to provide power to the DRBIII(R).
After making the above connections, you are able to select one or more updates that you want to
perform. These selections are made by highlighting the desired updates and then clicking on the
"Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client.
Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates
exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT
Client screen) will change color from GREEN to RED. At this point you must de-select entries until
the indicator changes color to GREEN again.
When the updates have finished downloading, you may disconnect from the TechCONNECT Client
and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R)
memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several
minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for
another 8 hours without power.
To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must
press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow
on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure
that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or
cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery
jump box".
Pay Attention While Performing Flash Reprogram Procedures
PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES
Before downloading the flash files, double check to see if the files that you have selected are the
appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option
on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files
selected don't download on the first attempt, try again.
The technician should NOT leave the vehicle when flash reprogramming a module.
Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a
stable surface. If you are using a battery charger, insure that the settings and charging times are
correct and that the battery post clamps are securely fastened.
Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part
number from the module that is to be flash reprogrammed.
Some control modules are not "abort-recovery" capable. When this is true, the scan tool will
indicate so by displaying a WARNING message prior to the start of reprogramming. For these
modules it is especially important that all precautions and procedures, outlined here, are carefully
followed.
Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or
"Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types
and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to
DRBIII(R) instructions.
Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled
prior to the start of reprogramming and re-installed immediately after completion. Be careful not to
anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the
many possible changes that occur with each new release of scan tool software, always allow the
TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming.
Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not
completed within 25 minutes after starting a flash reprogramming update, an error has most likely
occurred (Record the message that appears on the screen when a failure occurs). If this is the
case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the
locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power
up) before attempting to restart the flash process. If the module still won't respond, turn the ignition
key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the
ignition key to run and try to restart the flash process again.
Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have
tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were
followed, perform the following:
^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R).
(Push MORE and YES buttons at the same time, then press F4).
^ Reload the flash update file from the TechCONNECT Client.
^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before
re-attempting the flash download to the DRBIII(R).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4440
^ Proceed to reflash the module.
On vehicles that have multiple flash updates available, always complete and verify each flash
update before attempting the next one.
After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle.
A variety of DTCs may be set, which are usually related to a loss of communication with the
module(s) being reprogrammed.
Verify the update by reading the new part number using the DRBIII(R). A good double check is to
read the part number using DRBIII(R) stand alone.
At times, other modules, wired in parallel, to the DLC connector have prevented flash
reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring
diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other
modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules
that were disconnected. Refer to the "Programmable Modules" section later in this document for
more information.
Error Messages
ERROR MESSAGES
Block Echo/Compare Errors
Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables
(CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector.
Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable
recommendations.
Checksum Errors
Checksum Errors are generally caused by corrupt flash update files, which can be caused by
DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the
update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To
"Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press
"F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the
connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to
the DRBIII(R). Then re-attempt the flash reprogramming process.
Enhanced and Original Abort Recovery
ENHANCED ABORT RECOVERY
Interruptions in the flash process are one of the main reasons for failed flash sessions and
non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will
leave the control module in a non-functional state.
Generally, but not always, NR modules may be recovered successfully.
Briefly, abort recovery is the process used to get a NR module back to a fully functional state with
the latest software update. The technician should be familiar with the other sections in this
document and follow all DRBIII(R) user prompts carefully.
There are two methods for abort-recovery. The newer method is called "Enhanced Abort
Recovery". This is the preferred method since the original method takes several minutes longer
and requires the correct selection of module type from a list of possible PCM's or TCM's.
Starting with Release 60.1, a new useful feature was added to the flash reprogramming application
for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type
information to a "Safe Memory" location. This method allows for rapid recovery of the module part
number and minimizes errors that could otherwise be made by selecting the wrong controller type.
It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to
another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash
reprogramming you must erase the saved recovery information in order to successfully perform
flash reprogramming. Be careful to match the YME information displayed on the enhanced abort
recovery screen with the vehicle and module that you are attempting to recover. If you use the
recovery file on a different vehicle and module you could damage the module.
The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if
you previously encountered a problem that prevented a flash session from completing normally. If
your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that
the flash application will not show any recovery information at the start of your next flash session.
Enhanced abort recovery features:
^ Reduces the amount of time for the Module ID process.
^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and
Controller Type.
^ Currently only applicable to Engine and Transmission flash reprogramming.
^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the
user.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4441
^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the
enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be
reloaded.
^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort
recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the
original method of abort recovery.
^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller
into bootstrap (reprogramming) mode.
ORIGINAL ABORT RECOVERY
If the choice is made to use the original method of abort recovery, a NR module is not always able
to provide the DRBIII with ID information. In this case the technician must enter this when prompted
by the DRBIII(R). Be patient when performing this process. If the module does not respond to
standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the
engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not
determine engine controller type. Please select from list" along with a list of possible controller
types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of
"engine" and list the possible trans controller types). Because of module variations, it is important
to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do
this will cause further problems and may damage the module. Tables are provided below to help
identify the proper module type to select. These tables correctly identify the modules that were on
the vehicles when they were built. However, some vehicles will have module types which were
superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced
with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting
flash reprogramming.
NOTE:
When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to
the OFF position. The key must be rotated to the point at which it can be removed from the ignition
switch. On most vehicles the switch is on the steering column and at this position the steering
column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the
key past this position which may engage the starter motor. This creates electrical noise which
interferes with the flash process.
General Steps for Abort Recovery
1. Review all Tips and Techniques before continuing. Pay special attention to the section on
Preparing to Flash a controller and to the Programmable Modules section.
2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position.
3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and
then reconnecting the cable.
4. Depending on where the flash session was aborted, the DRBIII(R) may require that the
technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM
configuration table below as a guide. This step is not necessary if using the enhanced abort
recovery method.
5. After selecting the proper control module type or choosing enhanced abort recovery, follow the
prompts that are displayed on the DRBIII(R).
NOTE:
If an error message is displayed at this point, an incorrect module type was most likely selected. If
this occurs, start the process over.
6. If the recovery process is unsuccessful, perform the following:
a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this
document.
b. Reboot/Restart the TechCONNECT Client.
c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same
time, then press F4).
d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to
be reloaded from the TechCONNECT Client or ISIS DVD.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4442
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4443
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4444
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4445
Programmable Modules
The following pages list the various modules that have flash reprogramming capability. It does not
mean that a flash is currently available. What will be described are the module types and
variations, followed by items to note, and finally, abort recovery specifics if applicable.
Powertrain Modules - Engine and Transmission
ENGINE - POWERTRAIN CONTROL MODULE (PCM)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4446
There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are
somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the
module information and module type using your DRBII I®. PCM information is used by many
modules. Be sure to check DIG's before and after performing all flash reprogramming event.
The DTC's associated with flash reprogramming generally relate to "lack of communication" with
the other modules during the reprogramming session.
SBEC
Types:
SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B
NOTE:
During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to
PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON,
reconnect fuse or harness connection.
Abort Recovery Specifics:
^ Follow instructions on the DRBIII® for the module type. See table above.
^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly
identify a key cycle. In this case a Modified Key Cycle routine is required.
This state is present when the following message is displayed on the DRBIII(R): "Can not read Part
Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs
restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull
the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the
RUN position, replace the battery supply fuse(s) instead.
JTEC
Types:
^ JTEC, JTEC+
NOTE:
Viper ALL - Roll down windows especially Coupes before attempting a flash.
NOTE:
1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after
the PCM flash reprogramming session. Also see Transmission.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
NGC Types:
^ NGC 1, NGC 2, and NGC 3
NOTE:
There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC
modules use one of the longest time spans for flash reprogramming (approximately 15 minutes).
The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in
a common package. The NGC2 controller incorporates the engine controller and an Electronic
Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by
noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3
connectors may be populated with pins.
NOTE:
On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing
this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic
connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module
connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete
turn the ignition switch to the OFF position, connect the CAB module connector, and then check for
DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module
connector was not disconnected, then the PCM may be recovered by following the procedure in
this NOTE.
Abort Recovery Specifics:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4447
^ Follow DRBIII(R) prompts carefully.
^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the
flash.
CUMMINS
Types:
^ CM551 and CM84x series
NOTE:
Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine
Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine
Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s)
are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds.
SIEMENS
Types:
^ SIM-70
NOTE:
The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery
Specifics:
Follow DRBIII(R) prompts carefully.
BOSCH
Types:
^ EDC15V, EDC15-C5, and EDC16
NOTE:
While there have been other Bosch modules, the EDC15V is not flash reprogrammable.
Transmission controllers are usually flashed on the vehicle (since 1996).
Technicians may set the pinion factor on "NEW" modules either before or after flash
reprogramming. Suggestions follow.
After flash reprogramming and before returning the vehicle to the customer, always perform a
"QuickLearn" to the TCM.
EATX
Types:
^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A
NOTE:
Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a
service bulletin.
Abort Recovery Specifics:
^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part
numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is
completed during PIN verification. This DOES NOT mean the flash failed. Check for the part
number using DRBIII(R) in standalone mode. This exists only for the service replacement modules
listed above. Flash reprogramming for OE modules flash and read the part number correctly.
Follow DRBIII(R) prompts carefully.
NGC
Types:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4448
^ NGC1, NGC2, NGC3
NOTE:
The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not.
Vehicles with automatic transmissions using NGC2 will use an EATX4A.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the
CAB controller may need to be disconnected when attempting to flash the NGC controller. (This
should only be performed if an error occurs at the very beginning of the TCM flash portion.)
SIEMENS
Types:
^ EG552
NOTE:
EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel
engine (BUX), ZH Crossfire and VA Sprinter.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
JTEC
Types:
^ JTEC,JTEC+
NOTE:
Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also
provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are
used on some Cummins equipped Dodge trucks with manual and automatic transmissions.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
PRE 1996 EATX TRANSMISSION CONTROL MODULES
Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller
only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD
communications.
For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those
modules to the DRBIII(R) vehicle connector.
For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this
you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new"
(superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these
updated modules.
Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124.
The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin
18-24-95.
Types:
^ TCCM
NOTE:
These modules are found on AN, DN, and DR trucks.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4449
NON-POWERTRAIN CONTROL MODULES
BODY CONTROL MODULE (BCM)
Types:
^ BCM
NOTE:
Body control modules are found on passenger vehicles.
NOTE:
The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release
software version 52.25
^ 2001 LH - there is NO abort recovery available for the BCM.
CENTRAL TIMER MODULE (CTM)
Types:
^ CTM
NOTE:
CTMs are found on: AB, AN, DN, BR, and BE trucks.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
ELECTRONIC VEHICLE INFORMATION CENTER (EVIC)
Types:
^ EVIC
NOTE:
02-03 LH & WJ, and 03-04 KJ
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
FRONT CONTROL MODULE (FCM)
Types:
^ FCM
NOTE:
Front control modules are found on CS, DR, RG, and RS vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
INTEGRATED POWER MODULE (IPM)
Types:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4450
^ 1PM
NOTE:
Integrated power modules are found on CS, DR, RG, and RS vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
POWER LIFT GATE (PLG)
Types:
^ PLC
NOTE:
Power liftgate modules are found on CS and RS.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM)
Types:
^ PSDM
NOTE:
Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery
Specifics:
^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM)
Types:
^ DSDM
NOTE:
Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
NOTE:
When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you
must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module.
DRIVER DOOR MODULE (DDM)
Types:
^ DDM
NOTE:
Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM)
Types:
^ PDM
NOTE:
Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4451
Types:
^ MICs, eMICs
NOTE:
MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key
and pull a specific fuse.
^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and
is explained in the user prompts displayed during abort-recovery. Take the time to read and
understand the instructions before proceeding.
ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM)
Types:
^ ARKEM
NOTE:
Arkem modules are found on PL and PT vehicles. There are up to and after modules.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
CLIMATE CONTROL (ATC, HVAC)
Types:
^ HVAC, ATC, MTC
NOTE:
Generally, reprogramming for these modules is done using the standalone application rather than
the Vehicle Flash application.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully.
ADJUSTABLE PEDAL MODULE (APM)
Types:
^ APM
NOTE:
Found on CS, RS, and WJ vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
RAIN SENSOR MODULE (RSM)
Types:
^ RSM
NOTE:RSM modules are found on CS, RS, and WJ vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4452
INTRUSION TRANSCEIVER MODULE (ITM)
Types:
^ ITM
^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the
TSB for important instructions.
NOTE:
ITM modules are found on WJ (BUX) and KJ (BUX) vehicles.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully.
SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC.
Types:
^ SRS, ORC
NOTE:
While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to
support flash updates.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall
Technical Service Bulletin # 18-05-99 Date: 990226
PCM - Sag/Hesitation/Stumble/Stall
NUMBER: 18-05-99
GROUP: Vehicle Performance
DATE: Feb. 26, 1999
SUBJECT: Sags/Hesitation/Stumble/Start & Stall, A/C Bump Improvements, Addition Of Leak
Detection Pump (LDP) Monitor Test
OVERVIEW: This bulletin involves selectively erasing and reprogramming the powertrain control
module (PCM) with new software (calibration changes).
MODELS: 1997 - 1998 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION: 1997/1998 3.0L ATX Powertrains
^ Sags/Hesitation/Stumble/Start & Stall after a cold start in ambient temperatures of -7° - 30° C (20°
- 86° F). This condition may persist for up to a minute into a drive cycle and is attributed to high
driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index fuel.
1997/1998 2.4/3.0/3.3/3.8L Powertrains
^ Provides further enhancements to the software originally released in Technical Service Bulletins
18-19-97 Rev A dated Oct. 17, 1997 and 18-20-98 dated Apr. 17, 1998 for "Bump" Feel during A/C
Compressor Engagement. See TSB 18-19-97A and/or 18-20-98 for further details regarding this
subject.
1997/1998 2.4/3.0/3.3/3.8L Powertrains Equipped With Leak Detection Pump (1998 California
Emission (Sales Code NAE) only included LDP)
^ Addition of LDP Monitor Test. This test makes the DRB III(R) capable of running the LDP
monitor. This will allow technicians to verify LDP repairs easily.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool
(DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission
systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record
them on the repair order and repair as necessary before proceeding further with this bulletin. If no
DTC's are present and the customer has described the above symptoms, perform the Repair
Procedure.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE
LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED
CONTROLLERS AS NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 MDS1 or MDS2
NOTE:
THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF
USING THE MDSl AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR
HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2
AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4457
Labor Operation No: 08-19-42-98 0.5 Hrs.
FAILURE CODE: FM - Flash Module
MDS1 Procedure
1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
power them up.
2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R)
MAIN MENU SCREEN.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then
press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE
MDS1 & DRB III(R) on the MDS, then press NEXT MENU.
7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain
the current part number of the PCM.
8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s).
Press NEXT MENU to begin programming.
NOTE:
A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART
NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE
MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT
FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE
LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL
REQUIRE FURTHER INVESTIGATION.
9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
MDS2 Procedures
1. Log onto the MDS2 system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4458
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information
Technical Service Bulletin # 25-02-98 Date: 981023
I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information
MODELS:
1996 - 1999 (AB) Ram Van/Wagon
1996 - 1999 (AN) Dakota
1996 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1996 - 1999 (FJ) Avenger/Sebring/Talon
1996 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper Roadster/Coupe
1997 - 1999 (TJ) Wrangler
1999 (WJ) Grand Cherokee
1996 - 1999 (XJ) Cherokee
1996 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE
ENGINES.
DISCUSSION:
Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a
prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their
self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or
more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their
tests.
It is important to understand that the MIL will not be illuminated because OBD Readiness reads
"NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions
system occurs. It is possible to have MIL illumination for a detected failure while at the same time
having a "NO" for an OBO Readiness monitor.
NOTE:
MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER
DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS
BULLETIN.
OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM
replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items
occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for
OBD Readiness.
Some customers may be directed back to their dealers for assistance when an I/M test station has
not allowed an I/M test due to Readiness status. The following procedures will help technicians
efficiently run the Readiness tests so an owner can have their I/M test completed.
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7000/7001 J1962Cable
1 CH7OlO J1962 MMC Cable
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4463
TIME ALLOWANCE:
Labor Operation No: 25-01-01-91 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
This bulletin involves operating the vehicle under specific parameters to run or complete the OBD
monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions
application. In addition, the parameters to run each monitor will vary.
Preliminary Checks
1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate
as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit.
2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year
diagnostics, engine, DTC's and related functions, read DTC's.
3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the
engine running.
NOTE:
EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS
FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE
ATTEMPTING TO RUN THE MONITORS.
OBD "CARB" Readiness Check
1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status.
2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO"
tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned
to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read
"YES".
NOTE:
THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES
APPLICABLE FOR THE VEHICLE BEING WORKED ON.
The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to
run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The
pre-test/monitor test screen lists all the preliminary parameters that must be met along with the
running parameters for that specific monitor to run. An example of one screen is shown in Figure 1.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4464
NOTE:
1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN.
PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE
MONITORS RUN WILL BE SIMILAR.
The following explains how to interpret each section of the screen:
PRE-TEST REQUIREMENTS
The pre-test requirements include all the operating parameters that must be met before the actual
test can run. The vehicle must be operated until each item within the pre-test section are fulfilled.
LOW VALUE/HIGH VALUE/BAR GRAPH
The low value/high value provides the minimum and maximum operating conditions for each item
(ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when
the lowest value required for each item is met. This provides a visual indication that the parameters
are being met. The vehicle should be driven until most of each pre-test bar graph is filled.
MONITOR REQUIREMENTS
Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in
the monitor requirements section for the monitors to begin running. As the monitor begins to run,
the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle
operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician
must determine if the pre-test requirements or the monitor requirements have fallen outside the
window for the test and the vehicle must be driven accordingly for the test to restart. When the
monitor completes its test, the DRB III(R) will beep 3 consecutive times.
NOTE:
THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE
PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR
SCREEN FOR THIS MONITOR.
MONITOR RUN PROCESS
The following will provide the most efficient order along with tips to help run through the monitor
tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear
Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum
available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The
only monitors that will require attention are those that read "NO" under the OBD "CARB"
Readiness Status screen.
Front Wheel Drive
1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or out depending on conditions). The ambient (outside) temperature must be
between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining requirements.
2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the
requirements.
3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test
screen for this test to complete.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left
in drive for the test to run. If all parameters are met and the test still will not run, place your foot on
the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells
to update.
6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded.
This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No
Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater
monitor status. It should have switched to "YES". All other monitors should be completed before
running this test.
Rear Wheel Drive
1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either
indoors or outdoors depending on conditions). The ambient (outside) temperature must be between
18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4465
requirements.
2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must
be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F)
of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test
screen on the DRB III(R) to determine the remaining requirements.
3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet
the requirements.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transmission vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be
left in drive for the test to run. If all parameters are met and the test will still not run, place your foot
on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF
cells to update.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4470
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4471
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4472
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4473
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Improper
Cooling Fan Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for PROM - Programmable Read Only Memory: >
18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 4478
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery
Technical Service Bulletin # 18-037-05 Date: 051020
Engine Controls - Flash Programming Failure Recovery
NUMBER: 18-037-05
GROUP: Vehicle Performance
DATE: October 20, 2005
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-020-02, DATED JUNE 24, 2002 WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Flash Programming Failure Recovery Using DRBIII(R)
OVERVIEW: This Bulletin provides guidelines, to minimize flash reprogramming problems, and
information on recovery procedures for failed flash attempts.
MODELS:
1992 - 1994 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2003 (AB) Ramvan/Wagon
1992 - 1994 (AJ) Lebaron Coupe/Convertible
1995 - 2004 (AN) Dakota
1992 - 1995 (AS) Town & Country/Caravan/Voyager
1994 - 2002 (BRIBE) Ram Pickup
2004 - 2006 (CS) Pacifica
1998 - 2003 (DN) Durango
2002 - 2005 (DR/DH/D1) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1996 - 2000 (CS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2006 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2005 (KJ) Liberty/Cherokee (International Markets)
1993 - 2003 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2005 (PL) Neon
2002 (PG) PT Cruiser (International Markets)
1997 - 2002 (PR) Prowler
2001 - 2005 (PT) PT Cruiser
2001 - 2006 (RG) Chrysler Voyager (International Markets)
2001 - 2006 (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4484
1995 - 2002 (SR) Viper
2001 - 2005 (ST) Sebring Coupe/Stratus Coupe
1997 - 2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets)
1999 - 2004 (WJ) Grand Cherokee
1997 - 2001 (XJ) Cherokee
1993 - 1995 (YJ) Wrangler
2003 - 2006 (ZB) Viper
1995 - 1998 (ZG) Grand Cherokee (International Markets)
2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
NOTE:
Many of the reasons a flash reprogramming procedure may not complete are documented in this
service bulletin, but if you are constantly having issues performing the flash reprogramming
procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to
SPX/Miller Special Tools for service.
Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment
may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL
PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an
interruption or failure while reprogramming, are recoverable; a recoverable module is not covered
under the provisions of the warranty.
This service bulletin covers items that may cause this condition, a process to restart the flash
procedure, and miscellaneous information that will help prevent needless replacement of control
modules.
GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or
RECALL.
Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often
other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE
REQUIRED as part of completing the Service Bulletin/Recall.
When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there
are other legal requirements with labeling issues that are included in those service bulletins.
Other non-emission related modules, such as instrument clusters and Body Control Modules
(BCMs) do not require labels.
FLASH REPROGRAMMING SEQUENCE OF EVENTS
The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer.
Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere
with the process. This document seeks to provide information to minimize problems associated
with vehicle control module flash reprogramming. The description that follows is for most PCMs
and some TCMs. Other modules use different initiation procedures.
The process starts by selecting an update from the TechCONNECT Client or ISIS and then
"loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the
DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update
loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done
using part number supersedence. This verification occurs only if an update is required, available
(on the TechCONNECT Client or ISIS) and has been selected for programming.
^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module
mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming
session.
^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe
Memory" location within the module. This memory location is not affected by flash memory erasure
and reprogramming, which are to follow.
^ Once the part number is safely stored, the flash memory in the control module is erased. From
this point forward any interruption in the flash process,
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4485
will result in a Non-Responsive module (NR). A NR module is a module that is either partially
erased or partially programmed.
^ After erasure, the actual reprogramming procedure starts, and the update software is
programmed into the flash memory within the module.
^ When reprogramming is completed, the flash memory is verified through an internal process in
the DRBIII(R) using a "Check Sum". This value is compared against another value that represents
what should be in memory and when matched, verifies successful reprogramming.
^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The
module exits the "Boot Strap" mode when the switch is turned off.
^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The
DRBIII(R) then reads the new part number in flash memory (along with a new computer program
the new part number is placed into the module's memory). If the new part number matches the
expected part number, the flash reprogramming session has completed successfully.
SOFTWARE VERSIONS MUST BE CURRENT
Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you
have the most current DRBIII(R) software installed.
To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the
TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version.
Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The
installed DRBIII(R) software version can generally be found at the bottom center of most screens.
Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and
comparing it to what is available from a current TechCONNECT Client as described above.
If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the
TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new
support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is
why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions
installed.
DO NOT PASS on the option for updating to a "minor" revision!
Major updates require the DRBIII(R) to be updated prior to allowing any flash programming.
DRBIII(R) CABLES
A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft.
Cable, DRBIII(R) to OBDII (J1962) DLC Connector.
CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used
for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct
cable has a RED connector, which plugs into the DRBIII(R).
The cable modification enhances the DRBIII(R) communication capabilities when dealing with the
flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC
connector configurations.
The new cable is required for ALL flash reprogramming sessions, and can be used wherever the
previous CH700017001 cables were used.
While not recommended for flash reprogramming usage, if you require a longer cable, there is also
a 12-foot cable released under pin CH7001A
The production of the previous CH700017001 cables has ceased. All orders placed will be
superseded to part number CH7000A/CH7001A.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4486
NOTE:
Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are
damaged or do not lock securely, and all mating connections including checking for corrosion on
the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash
reprogramming.
Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming
sessions.
The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O
cable (Pre-OBDII MMC vehicles will use the CH7005 cable).
TechCONNECT CABLE (GPIB)
Replace any suspect GPIB cable.
The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R).
This cable is used by the TechCONNECT Client for vehicle part number reads and to send update
files to the DRBIII(R).
Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If
this cable becomes disconnected during a flash session, you may have to reload the update file
that you selected on the TechCONNECT Client.
TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT
APPLICATION.
1. Turn-on the power to the DRBIII(R) unit.
2. Select option 2 "Connect to TechCONNECT" and press Enter.
3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number
CH7035B) to the DRBIII(R) unit.
4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is
properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol
converter, (part number CHGPIB-B).
5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the
rear panel of the client CPU.
6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will
detect the device and install software for it. Please wait for 25-30 seconds to complete the
installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4487
ISIS NULL MODEM CABLE
Replace any suspect null modem cables.
International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem
cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for
loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes
disconnected during a flash download session, you will have to reload the update file or files.
GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS
Consider ALL cables to be wear items.
Many successful dealers have dedicated cables devoted to "Flash ONLY".
Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available.
Inspect vehicle diagnostic connectors for potential problems that might cause communication
interruptions.
There are now clip repair kits available through teamPSE to replace the retaining clips for two of
these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above
25 lbs. of axial force. Kits are described in the table.
It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general
damage beyond the retaining clips.
ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4488
These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT)
was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded
from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users
should closely follow the instructions that come with the tool. If the tool has not been initialized,
there is a known condition where it may take up to 5 or more attempts for it to fully initialize and
become functional.
NOTE:
Once it has successfully flashed, it is initialized and no further action is required.
PREPARING TO FLASH
It is highly recommended that a sign, or other process, be used that notifies other users that a
FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash
reprogramming sessions at critical junctures can render a module inoperative. Another user may
not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do
something on the vehicle that could interrupt the flash process.
Before starting the flash session, read, record and erase all DTCs found on the vehicle.
Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the
DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the
same time. Then press "F4").
Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an
area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it
rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have
been known to be swept off vehicle windshields by accident when a user bumps the wiper switch).
Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to
make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash
reprogramming errors may occur.
VEHICLE BATTERY VOLTAGE
The flash programming procedure puts a load on the electrical system that may last from five to
twenty minutes depending on the particular flash reprogramming update. Connect a battery
charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a
timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to
prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by
voltage fluctuations.
Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to
ensure adequate and stable system voltages on the module being flash reprogrammed.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Connected/Disconnected Flash Mode Using TechCONNECT
CONNECTED MODE FLASHING USING TechCONNECT
NOTE:
Capable but not recommended.
In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle
throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the
GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most
vehicles).
This mode is useful when the TechCONNECT Client is next to the vehicle being flashed.
Another advantage of this mode is that you are able to determine all available flash updates for the
vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button.
Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client
while a flash update is in-progress.
The reprogramming procedure of this mode is initiated by selecting the controller option and
clicking "Download/Update" button on the TechCONNECT client.
DISCONNECTED FLASH MODE
NOTE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4489
This is the preferred method.
This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client.
This is a popular mode for flashing in a remote area of the service garage or in a back lot.
Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s).
To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and
the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will
be used to communicate with the TechCONNECT Client (for update file downloading) while the
CH7025 cable is used to provide power to the DRBIII(R).
After making the above connections, you are able to select one or more updates that you want to
perform. These selections are made by highlighting the desired updates and then clicking on the
"Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client.
Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates
exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT
Client screen) will change color from GREEN to RED. At this point you must de-select entries until
the indicator changes color to GREEN again.
When the updates have finished downloading, you may disconnect from the TechCONNECT Client
and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R)
memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several
minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for
another 8 hours without power.
To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must
press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow
on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure
that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or
cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery
jump box".
Pay Attention While Performing Flash Reprogram Procedures
PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES
Before downloading the flash files, double check to see if the files that you have selected are the
appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option
on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files
selected don't download on the first attempt, try again.
The technician should NOT leave the vehicle when flash reprogramming a module.
Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a
stable surface. If you are using a battery charger, insure that the settings and charging times are
correct and that the battery post clamps are securely fastened.
Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part
number from the module that is to be flash reprogrammed.
Some control modules are not "abort-recovery" capable. When this is true, the scan tool will
indicate so by displaying a WARNING message prior to the start of reprogramming. For these
modules it is especially important that all precautions and procedures, outlined here, are carefully
followed.
Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or
"Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types
and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to
DRBIII(R) instructions.
Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled
prior to the start of reprogramming and re-installed immediately after completion. Be careful not to
anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the
many possible changes that occur with each new release of scan tool software, always allow the
TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming.
Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not
completed within 25 minutes after starting a flash reprogramming update, an error has most likely
occurred (Record the message that appears on the screen when a failure occurs). If this is the
case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the
locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power
up) before attempting to restart the flash process. If the module still won't respond, turn the ignition
key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the
ignition key to run and try to restart the flash process again.
Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have
tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were
followed, perform the following:
^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R).
(Push MORE and YES buttons at the same time, then press F4).
^ Reload the flash update file from the TechCONNECT Client.
^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before
re-attempting the flash download to the DRBIII(R).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4490
^ Proceed to reflash the module.
On vehicles that have multiple flash updates available, always complete and verify each flash
update before attempting the next one.
After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle.
A variety of DTCs may be set, which are usually related to a loss of communication with the
module(s) being reprogrammed.
Verify the update by reading the new part number using the DRBIII(R). A good double check is to
read the part number using DRBIII(R) stand alone.
At times, other modules, wired in parallel, to the DLC connector have prevented flash
reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring
diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other
modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules
that were disconnected. Refer to the "Programmable Modules" section later in this document for
more information.
Error Messages
ERROR MESSAGES
Block Echo/Compare Errors
Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables
(CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector.
Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable
recommendations.
Checksum Errors
Checksum Errors are generally caused by corrupt flash update files, which can be caused by
DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the
update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To
"Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press
"F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the
connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to
the DRBIII(R). Then re-attempt the flash reprogramming process.
Enhanced and Original Abort Recovery
ENHANCED ABORT RECOVERY
Interruptions in the flash process are one of the main reasons for failed flash sessions and
non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will
leave the control module in a non-functional state.
Generally, but not always, NR modules may be recovered successfully.
Briefly, abort recovery is the process used to get a NR module back to a fully functional state with
the latest software update. The technician should be familiar with the other sections in this
document and follow all DRBIII(R) user prompts carefully.
There are two methods for abort-recovery. The newer method is called "Enhanced Abort
Recovery". This is the preferred method since the original method takes several minutes longer
and requires the correct selection of module type from a list of possible PCM's or TCM's.
Starting with Release 60.1, a new useful feature was added to the flash reprogramming application
for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type
information to a "Safe Memory" location. This method allows for rapid recovery of the module part
number and minimizes errors that could otherwise be made by selecting the wrong controller type.
It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to
another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash
reprogramming you must erase the saved recovery information in order to successfully perform
flash reprogramming. Be careful to match the YME information displayed on the enhanced abort
recovery screen with the vehicle and module that you are attempting to recover. If you use the
recovery file on a different vehicle and module you could damage the module.
The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if
you previously encountered a problem that prevented a flash session from completing normally. If
your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that
the flash application will not show any recovery information at the start of your next flash session.
Enhanced abort recovery features:
^ Reduces the amount of time for the Module ID process.
^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and
Controller Type.
^ Currently only applicable to Engine and Transmission flash reprogramming.
^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the
user.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4491
^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the
enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be
reloaded.
^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort
recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the
original method of abort recovery.
^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller
into bootstrap (reprogramming) mode.
ORIGINAL ABORT RECOVERY
If the choice is made to use the original method of abort recovery, a NR module is not always able
to provide the DRBIII with ID information. In this case the technician must enter this when prompted
by the DRBIII(R). Be patient when performing this process. If the module does not respond to
standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the
engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not
determine engine controller type. Please select from list" along with a list of possible controller
types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of
"engine" and list the possible trans controller types). Because of module variations, it is important
to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do
this will cause further problems and may damage the module. Tables are provided below to help
identify the proper module type to select. These tables correctly identify the modules that were on
the vehicles when they were built. However, some vehicles will have module types which were
superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced
with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting
flash reprogramming.
NOTE:
When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to
the OFF position. The key must be rotated to the point at which it can be removed from the ignition
switch. On most vehicles the switch is on the steering column and at this position the steering
column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the
key past this position which may engage the starter motor. This creates electrical noise which
interferes with the flash process.
General Steps for Abort Recovery
1. Review all Tips and Techniques before continuing. Pay special attention to the section on
Preparing to Flash a controller and to the Programmable Modules section.
2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position.
3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and
then reconnecting the cable.
4. Depending on where the flash session was aborted, the DRBIII(R) may require that the
technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM
configuration table below as a guide. This step is not necessary if using the enhanced abort
recovery method.
5. After selecting the proper control module type or choosing enhanced abort recovery, follow the
prompts that are displayed on the DRBIII(R).
NOTE:
If an error message is displayed at this point, an incorrect module type was most likely selected. If
this occurs, start the process over.
6. If the recovery process is unsuccessful, perform the following:
a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this
document.
b. Reboot/Restart the TechCONNECT Client.
c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same
time, then press F4).
d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to
be reloaded from the TechCONNECT Client or ISIS DVD.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4492
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4493
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4494
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4495
Programmable Modules
The following pages list the various modules that have flash reprogramming capability. It does not
mean that a flash is currently available. What will be described are the module types and
variations, followed by items to note, and finally, abort recovery specifics if applicable.
Powertrain Modules - Engine and Transmission
ENGINE - POWERTRAIN CONTROL MODULE (PCM)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4496
There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are
somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the
module information and module type using your DRBII I®. PCM information is used by many
modules. Be sure to check DIG's before and after performing all flash reprogramming event.
The DTC's associated with flash reprogramming generally relate to "lack of communication" with
the other modules during the reprogramming session.
SBEC
Types:
SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B
NOTE:
During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to
PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON,
reconnect fuse or harness connection.
Abort Recovery Specifics:
^ Follow instructions on the DRBIII® for the module type. See table above.
^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly
identify a key cycle. In this case a Modified Key Cycle routine is required.
This state is present when the following message is displayed on the DRBIII(R): "Can not read Part
Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs
restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull
the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the
RUN position, replace the battery supply fuse(s) instead.
JTEC
Types:
^ JTEC, JTEC+
NOTE:
Viper ALL - Roll down windows especially Coupes before attempting a flash.
NOTE:
1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after
the PCM flash reprogramming session. Also see Transmission.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
NGC Types:
^ NGC 1, NGC 2, and NGC 3
NOTE:
There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC
modules use one of the longest time spans for flash reprogramming (approximately 15 minutes).
The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in
a common package. The NGC2 controller incorporates the engine controller and an Electronic
Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by
noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3
connectors may be populated with pins.
NOTE:
On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing
this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic
connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module
connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete
turn the ignition switch to the OFF position, connect the CAB module connector, and then check for
DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module
connector was not disconnected, then the PCM may be recovered by following the procedure in
this NOTE.
Abort Recovery Specifics:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4497
^ Follow DRBIII(R) prompts carefully.
^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the
flash.
CUMMINS
Types:
^ CM551 and CM84x series
NOTE:
Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine
Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine
Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s)
are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds.
SIEMENS
Types:
^ SIM-70
NOTE:
The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery
Specifics:
Follow DRBIII(R) prompts carefully.
BOSCH
Types:
^ EDC15V, EDC15-C5, and EDC16
NOTE:
While there have been other Bosch modules, the EDC15V is not flash reprogrammable.
Transmission controllers are usually flashed on the vehicle (since 1996).
Technicians may set the pinion factor on "NEW" modules either before or after flash
reprogramming. Suggestions follow.
After flash reprogramming and before returning the vehicle to the customer, always perform a
"QuickLearn" to the TCM.
EATX
Types:
^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A
NOTE:
Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a
service bulletin.
Abort Recovery Specifics:
^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part
numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is
completed during PIN verification. This DOES NOT mean the flash failed. Check for the part
number using DRBIII(R) in standalone mode. This exists only for the service replacement modules
listed above. Flash reprogramming for OE modules flash and read the part number correctly.
Follow DRBIII(R) prompts carefully.
NGC
Types:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4498
^ NGC1, NGC2, NGC3
NOTE:
The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not.
Vehicles with automatic transmissions using NGC2 will use an EATX4A.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the
CAB controller may need to be disconnected when attempting to flash the NGC controller. (This
should only be performed if an error occurs at the very beginning of the TCM flash portion.)
SIEMENS
Types:
^ EG552
NOTE:
EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel
engine (BUX), ZH Crossfire and VA Sprinter.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
JTEC
Types:
^ JTEC,JTEC+
NOTE:
Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also
provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are
used on some Cummins equipped Dodge trucks with manual and automatic transmissions.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
PRE 1996 EATX TRANSMISSION CONTROL MODULES
Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller
only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD
communications.
For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those
modules to the DRBIII(R) vehicle connector.
For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this
you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new"
(superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these
updated modules.
Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124.
The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin
18-24-95.
Types:
^ TCCM
NOTE:
These modules are found on AN, DN, and DR trucks.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4499
NON-POWERTRAIN CONTROL MODULES
BODY CONTROL MODULE (BCM)
Types:
^ BCM
NOTE:
Body control modules are found on passenger vehicles.
NOTE:
The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release
software version 52.25
^ 2001 LH - there is NO abort recovery available for the BCM.
CENTRAL TIMER MODULE (CTM)
Types:
^ CTM
NOTE:
CTMs are found on: AB, AN, DN, BR, and BE trucks.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
ELECTRONIC VEHICLE INFORMATION CENTER (EVIC)
Types:
^ EVIC
NOTE:
02-03 LH & WJ, and 03-04 KJ
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
FRONT CONTROL MODULE (FCM)
Types:
^ FCM
NOTE:
Front control modules are found on CS, DR, RG, and RS vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
INTEGRATED POWER MODULE (IPM)
Types:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4500
^ 1PM
NOTE:
Integrated power modules are found on CS, DR, RG, and RS vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
POWER LIFT GATE (PLG)
Types:
^ PLC
NOTE:
Power liftgate modules are found on CS and RS.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM)
Types:
^ PSDM
NOTE:
Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery
Specifics:
^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM)
Types:
^ DSDM
NOTE:
Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
NOTE:
When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you
must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module.
DRIVER DOOR MODULE (DDM)
Types:
^ DDM
NOTE:
Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM)
Types:
^ PDM
NOTE:
Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4501
Types:
^ MICs, eMICs
NOTE:
MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key
and pull a specific fuse.
^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and
is explained in the user prompts displayed during abort-recovery. Take the time to read and
understand the instructions before proceeding.
ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM)
Types:
^ ARKEM
NOTE:
Arkem modules are found on PL and PT vehicles. There are up to and after modules.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
CLIMATE CONTROL (ATC, HVAC)
Types:
^ HVAC, ATC, MTC
NOTE:
Generally, reprogramming for these modules is done using the standalone application rather than
the Vehicle Flash application.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully.
ADJUSTABLE PEDAL MODULE (APM)
Types:
^ APM
NOTE:
Found on CS, RS, and WJ vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
RAIN SENSOR MODULE (RSM)
Types:
^ RSM
NOTE:RSM modules are found on CS, RS, and WJ vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4502
INTRUSION TRANSCEIVER MODULE (ITM)
Types:
^ ITM
^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the
TSB for important instructions.
NOTE:
ITM modules are found on WJ (BUX) and KJ (BUX) vehicles.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully.
SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC.
Types:
^ SRS, ORC
NOTE:
While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to
support flash updates.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall
Technical Service Bulletin # 18-05-99 Date: 990226
PCM - Sag/Hesitation/Stumble/Stall
NUMBER: 18-05-99
GROUP: Vehicle Performance
DATE: Feb. 26, 1999
SUBJECT: Sags/Hesitation/Stumble/Start & Stall, A/C Bump Improvements, Addition Of Leak
Detection Pump (LDP) Monitor Test
OVERVIEW: This bulletin involves selectively erasing and reprogramming the powertrain control
module (PCM) with new software (calibration changes).
MODELS: 1997 - 1998 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION: 1997/1998 3.0L ATX Powertrains
^ Sags/Hesitation/Stumble/Start & Stall after a cold start in ambient temperatures of -7° - 30° C (20°
- 86° F). This condition may persist for up to a minute into a drive cycle and is attributed to high
driveability index (DI) fuel. See TSB 14-08-97 for more detail on Driveability Index fuel.
1997/1998 2.4/3.0/3.3/3.8L Powertrains
^ Provides further enhancements to the software originally released in Technical Service Bulletins
18-19-97 Rev A dated Oct. 17, 1997 and 18-20-98 dated Apr. 17, 1998 for "Bump" Feel during A/C
Compressor Engagement. See TSB 18-19-97A and/or 18-20-98 for further details regarding this
subject.
1997/1998 2.4/3.0/3.3/3.8L Powertrains Equipped With Leak Detection Pump (1998 California
Emission (Sales Code NAE) only included LDP)
^ Addition of LDP Monitor Test. This test makes the DRB III(R) capable of running the LDP
monitor. This will allow technicians to verify LDP repairs easily.
DIAGNOSIS: Using the Mopar Diagnostic System (MDS/MDS2) and or the Diagnostic Scan Tool
(DRB III(R)) with the appropriate Diagnostic Procedures Manual, verify all engine/transmission
systems are functioning as designed. If Diagnostic Trouble Codes (DTC's) are present, record
them on the repair order and repair as necessary before proceeding further with this bulletin. If no
DTC's are present and the customer has described the above symptoms, perform the Repair
Procedure.
NOTE:
WHENEVER A POWERTRAIN CONTROL MODULE (PCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE REPLACEMENT CONTROLLER MUST BE VERIFIED FOR THE
LATEST REVISION LEVEL. USE THE FLASH PROCEDURE TO UPDATE REPLACED
CONTROLLERS AS NECESSARY.
PARTS REQUIRED:
1 04669020 Label, Authorized Software Update
1 04275086 Label, Authorized Modification
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7OOO/7001 J1962 Cable
1 MDS1 or MDS2
NOTE:
THE MDS1/MDS2 AND DRB III(R) ARE REQUIRED TO PERFORM PART OF THIS REPAIR. IF
USING THE MDSl AND DRB III(R) THE MDS MUST BE OPERATING AT RELEASE 21 OR
HIGHER AND TIL CD RELEASE 1179 OR HIGHER MUST BE INSTALLED. IF USING THE MDS2
AND DRB III(R) THE SYSTEM MUST BE OPERATING AT CIS CD2030 OR HIGHER.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4507
Labor Operation No: 08-19-42-98 0.5 Hrs.
FAILURE CODE: FM - Flash Module
MDS1 Procedure
1. Connect the MDS1 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
power them up.
2. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
3. Use the arrow keys and select MDS DIAGNOSTICS OR DRB III(R) UPDATE on the DRB III(R)
MAIN MENU SCREEN.
4. Use the arrow keys and select DIAGNOSTIC MENU on the MDS1, then press NEXT MENU.
5. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS1, then
press NEXT MENU.
6. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING THE
MDS1 & DRB III(R) on the MDS, then press NEXT MENU.
7. Follow the steps presented on the MDS1 and DRB III(R) that will allow the DRB III(R) to obtain
the current part number of the PCM.
8. The MDS1 will display the vehicle's PCM part number and the replacement part number(s).
Press NEXT MENU to begin programming.
NOTE:
A NO UPDATES AVAILABLE MESSAGE MAY BE DISPLAYED. CHECK THE PCM PART
NUMBER ON THE VEHICLE AND COMPARE IT TO THE PART NUMBER DISPLAYED ON THE
MDS. IF NO UPDATES ARE AVAILABLE, FIRST CHECK YOUR DIAGNOSTIC EQUIPMENT
FOR THE LATEST SOFTWARE LEVELS AS LISTED EARLIER IN THIS BULLETIN. IF THE
LATEST SOFTWARE IS INSTALLED, ANOTHER VEHICLE CONDITION EXISTS THAT WILL
REQUIRE FURTHER INVESTIGATION.
9. The MDS1 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
10. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
11. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
MDS2 Procedures
1. Log onto the MDS2 system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-05-99 > Feb > 99 > PCM - Sag/Hesitation/Stumble/Stall > Page 4508
2. Connect the MDS2 (Mopar Diagnostic System) and DRB III(R) (Scan Tool) to the vehicle and
switch the ignition key to "ON".
3. Use the arrow keys and select # 2 CONNECT TO MDS1 OR MDS2 on the DRB III(R) MAIN
MENU SCREEN.
4. Use the arrow keys and select # 2 RUN MDS2 APPLICATION on the DRB III(R) MAIN MENU
SCREEN.
NOTE:
ONCE MDS2, DRB III(R), AND VEHICLE COMMUNICATION HAS BEEN ESTABLISHED, THE
CANNOT READ VIN FROM DRB III(R) MESSAGE (ON THE MDS2) WILL BE REPLACED BY
THE VEHICLE VIN. PRESS THE "OK" BUTTON ON THE MDS2 TO REQUEST A MDS2
SESSION FOR THE VEHICLE VIN INDICATED. PRESS THE "OK" BUTTON WHEN ASKED TO
BEGIN SESSION.
5. Push the FLASH tab on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
6. Select READ PART NUMBERS FROM VEHICLE and click SHOW UPDATES on the MDS2.
NOTE:
A MESSAGE MAY APPEAR THAT INDICATES NO UPDATES ARE AVAILABLE. IF THIS
OCCURS, MAKE SURE YOUR DIAGNOSTIC EQUIPMENT IS OPERATING AT THE LATEST
SOFTWARE LEVEL AS LISTED EARLIER IN THIS BULLETIN. IF THE LATEST SOFTWARE IS
INSTALLED, AND NO UPDATES ARE AVAILABLE, ANOTHER VEHICLE CONDITION EXISTS
THAT WILL REQUIRE FURTHER INVESTIGATION.
7. Select the new software part number with the light pen and click UPDATE CONTROLLER
SOFTWARE.
8. The MDS2 and DRB III(R) will prompt for any operator action needed during the remainder of
the reprogramming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI label (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information
Technical Service Bulletin # 25-02-98 Date: 981023
I/M Testing - OBDII CARB Readiness Monitor Information
NO: 25-02-98
GROUP: Emissions
DATE: Oct. 23, 1998
SUBJECT:
I/M (Inspection Maintenance) Testing - OBD II "CARB" Readiness Monitor Information
MODELS:
1996 - 1999 (AB) Ram Van/Wagon
1996 - 1999 (AN) Dakota
1996 - 1999 (BR/BE) Ram Truck
1998 - 1999 (DN) Durango
1996 - 1999 (FJ) Avenger/Sebring/Talon
1996 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1996 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1995 - 1999 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper Roadster/Coupe
1997 - 1999 (TJ) Wrangler
1999 (WJ) Grand Cherokee
1996 - 1999 (XJ) Cherokee
1996 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS INFORMATION APPLIES TO NATURALLY ASPIRATED (NON-TURBO) GASOLINE
ENGINES.
DISCUSSION:
Some states that require I/M inspections are beginning to include OBD II "CARB" Readiness as a
prerequisite to an I/M test. OBD Readiness tells an I/M station if the OBD II systems have run their
self test. Owners, in those states that use OBD Readiness, may be denied an I/M test if one or
more of the Readiness monitors read "NO" or in other words the OBD II monitors have not run their
tests.
It is important to understand that the MIL will not be illuminated because OBD Readiness reads
"NO". MIL illumination happens when an actual malfunction or failure of a monitored emissions
system occurs. It is possible to have MIL illumination for a detected failure while at the same time
having a "NO" for an OBO Readiness monitor.
NOTE:
MIL ILLUMINATION INDICATES ADDITIONAL PROBLEMS WITH THE VEHICLE. FURTHER
DIAGNOSIS AND REPAIR WILL BE REQUIRED BEFORE PROCEEDING FURTHER WITH THIS
BULLETIN.
OBD Readiness that reads "NO" can be caused by the following: PCM reprogramming, PCM
replacement, fault code erasure, battery disconnects and/or replacement. If any of the above items
occur before an I/M test, a good chance exists that one or more of the monitors will read "NO" for
OBD Readiness.
Some customers may be directed back to their dealers for assistance when an I/M test station has
not allowed an I/M test due to Readiness status. The following procedures will help technicians
efficiently run the Readiness tests so an owner can have their I/M test completed.
EQUIPMENT REQUIRED:
1 CH6OOO Scan Tool (DRB III(R))
1 CH7000/7001 J1962Cable
1 CH7OlO J1962 MMC Cable
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4513
TIME ALLOWANCE:
Labor Operation No: 25-01-01-91 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
This bulletin involves operating the vehicle under specific parameters to run or complete the OBD
monitors. The number of monitors applicable to a vehicle will vary by type of vehicle and emissions
application. In addition, the parameters to run each monitor will vary.
Preliminary Checks
1. Perform a MIL bulb check by switching the ignition key "ON" (engine off). The MIL will illuminate
as a bulb check. If the MIL does not illuminate, repair the bulb or bulb circuit.
2. Connect a DRB III(R) to the vehicle. Select DRB III(R) standalone, current model year
diagnostics, engine, DTC's and related functions, read DTC's.
3. Verity that no emission related DTC's are present and that the MIL is not illuminated with the
engine running.
NOTE:
EMISSION RELATED DTC'S AND MIL ILLUMINATION MAY PREVENT OTHER OBD MONITORS
FROM RUNNING. DTC'S THAT ILLUMINATE THE MIL MUST BE REPAIRED BEFORE
ATTEMPTING TO RUN THE MONITORS.
OBD "CARB" Readiness Check
1. With the DRB III(R) select engine, OBD II monitors, CARB Readiness Status.
2. Read the monitor status. "YES" tells you that monitor has run and is ready for an I/M test, "NO"
tells you that the monitor must be run. If all monitors listed read "YES", the vehicle can be returned
to the customer for completion of their I/M test. Only monitors that read "NO" must be run to read
"YES".
NOTE:
THE MONITORS LISTED IN THE OBD "CARB" READINESS SCREEN ARE THE ONLY ONES
APPLICABLE FOR THE VEHICLE BEING WORKED ON.
The vehicle must be operated in various conditions (speed, temperature, etc.) for the monitors to
run. Each monitor includes a pre-test and monitor test that can be viewed on the DRB III(R). The
pre-test/monitor test screen lists all the preliminary parameters that must be met along with the
running parameters for that specific monitor to run. An example of one screen is shown in Figure 1.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4514
NOTE:
1997 AND PREVIOUS MODEL VEHICLES WILL HAVE A DIFFERENT LOOKING SCREEN.
PRESS THE F1 KEY TO OBTAIN MONITOR RUN CONDITIONS. THE WAY IN WHICH THE
MONITORS RUN WILL BE SIMILAR.
The following explains how to interpret each section of the screen:
PRE-TEST REQUIREMENTS
The pre-test requirements include all the operating parameters that must be met before the actual
test can run. The vehicle must be operated until each item within the pre-test section are fulfilled.
LOW VALUE/HIGH VALUE/BAR GRAPH
The low value/high value provides the minimum and maximum operating conditions for each item
(ie ECT Range must be between 170° and 260° F in Figure 1). The bar graph will begin to fill when
the lowest value required for each item is met. This provides a visual indication that the parameters
are being met. The vehicle should be driven until most of each pre-test bar graph is filled.
MONITOR REQUIREMENTS
Once all pre-test requirements are met, the vehicle must be brought within the parameters listed in
the monitor requirements section for the monitors to begin running. As the monitor begins to run,
the DRB III(R) will begin to beep. This is an audible indication that the test is in progress. If vehicle
operation falls outside any of the parameters, the beeping will stop. If this occurs, the technician
must determine if the pre-test requirements or the monitor requirements have fallen outside the
window for the test and the vehicle must be driven accordingly for the test to restart. When the
monitor completes its test, the DRB III(R) will beep 3 consecutive times.
NOTE:
THE PURGE FLOW PRE-TEST SCREEN WILL LOOK DIFFERENT THAN THE REST OF THE
PRE-TEST/MONITOR SCREENS. PRESS THE F1 KEY ON THE DRB III(R) TO SEE A SIMILAR
SCREEN FOR THIS MONITOR.
MONITOR RUN PROCESS
The following will provide the most efficient order along with tips to help run through the monitor
tests quickly. The monitors listed include all possible monitors for either Front Wheel Drive or Rear
Wheel Drive vehicles. The vehicle being worked on may have fewer monitors than the maximum
available. Only those listed on the DRB III(R) are applicable for the vehicle being worked on. The
only monitors that will require attention are those that read "NO" under the OBD "CARB"
Readiness Status screen.
Front Wheel Drive
1. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or out depending on conditions). The ambient (outside) temperature must be
between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining requirements.
2. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transaxle, use fourth gear to help meet the
requirements.
3. EGR Monitor - It is necessary to maintain TPS, MAP, and RPM ranges listed in the pre-test
screen for this test to complete.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transaxle vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transaxle vehicles must be left
in drive for the test to run. If all parameters are met and the test still will not run, place your foot on
the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF cells
to update.
6. O2 Sensor Heater Monitor - The open throttle time for the O2 Heater pre-test must be exceeded.
This monitor will run after the ignition key is switched "Off". After the DRB III(R) switches to No
Response (approximately 3 minutes) turn the ignition key "On" and check the O2 Sensor Heater
monitor status. It should have switched to "YES". All other monitors should be completed before
running this test.
Rear Wheel Drive
1. O2 Sensor Heater Monitor - This test will require a cold start (possibly an overnight soak either
indoors or outdoors depending on conditions). The ambient (outside) temperature must be between
18° and 38° C (0° and 100° F with the engine coolant temperature within 6° C (10° F) of
ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test screen
on the DRB III(R) to determine the remaining
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
25-02-98 > Oct > 98 > I/M Testing - OBDII CARB Readiness Monitor Information > Page 4515
requirements.
2. Evaporative Leak Detection Monitor - This test will require a cold start (possibly an overnight
soak either indoors or outdoors depending on conditions). The ambient (outside) temperature must
be between 4° and 32° C (40° and 90° F) with the engine coolant temperature within 6° C (10 ° F)
of ambient/battery temperature. Once the above criteria are met, use the pre-test/monitor test
screen on the DRB III(R) to determine the remaining requirements.
3. Catalyst Monitor - The vehicle must be driven at highway speeds for the time listed in the
pre-test screen. If the vehicle is equipped with a manual transmission, use 4th gear to help meet
the requirements.
4. O2 Sensor Monitor - The vehicle must be driven and brought to a stop for the time listed in the
pre-test screen. Automatic transmission vehicles must be left in drive during the stop period.
5. Purge Monitor - To see a similar screen format as listed in Figure 1, press the F1 key on the
DRB III(R) while in the Purge Flow Pre-Test screen. The purge free (PF) cells must update and the
monitor will attempt to run on every other throttle closure. Automatic transmission vehicles must be
left in drive for the test to run. If all parameters are met and the test will still not run, place your foot
on the brake, open the throttle to 1/4 and then quickly close the throttle. This should allow the PF
cells to update.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation
PROM - Programmable Read Only Memory: All Technical Service Bulletins PCM - Improper
Cooling Fan Relay Actuation
NO: 18-33-97
GROUP: Vehicle Performance
DATE: Dec. 31, 1997
SUBJECT: Improper Cooling Fan Relay Actuation
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 2.4L, 3.3L OR 3.8L ENGINE BUILT
PRIOR TO DEC. 1, 1997 (MDH 1201 XX).
DISCUSSION: The software within the powertrain control module (PCM) may not operate or drive
the solid state relay for the radiator fan correctly. The vehicle could eventually exhibit an overheat
condition due to cooling fan relay failure.
NOTE:
ALL IN STOCK OR IN TRANSIT VEHICLES BUILT PRIOR TO THE ABOVE CLEAN POINT
SHOULD BE FLASH UPDATED PRIOR TO CUSTOMER DELIVERY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM THIS REPAIR AND THE SYSTEM
MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1146 OR
HIGHER MUST BE INSTALLED.
REPAIR PROCEDURE: This bulletin involves selectively erasing and reprogramming the
Powertrain Control Module (PCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the PCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the PCM on the vehicle and compare it to the
part number displayed. If the PCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-33-97 > Dec > 97 > PCM - Improper Cooling Fan Relay Actuation > Page 4520
9. Type the necessary information on the "Authorized Software Update Label" p/n 04669020
(Figure 1). Attach the label to the PCM and cover the label with the clear plastic overlay.
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-19-49-90 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4526
1995 - 2002 (SR) Viper
2001 - 2005 (ST) Sebring Coupe/Stratus Coupe
1997 - 2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets)
1999 - 2004 (WJ) Grand Cherokee
1997 - 2001 (XJ) Cherokee
1993 - 1995 (YJ) Wrangler
2003 - 2006 (ZB) Viper
1995 - 1998 (ZG) Grand Cherokee (International Markets)
2004 - 2006 (ZH) Crossfire Coupe/Crossfire Roadster
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
NOTE:
Many of the reasons a flash reprogramming procedure may not complete are documented in this
service bulletin, but if you are constantly having issues performing the flash reprogramming
procedure using a specific DRBIII(R), it is suggested you send the DRBIII(R) in question to
SPX/Miller Special Tools for service.
Occasionally a flash update procedure may not complete properly and/or the diagnostic equipment
may lock up or become disconnected during the procedure. Flash Reprogramming is a "CRITICAL
PROCESS"; an error may result in a no-start/failed control module. Most modules, encountering an
interruption or failure while reprogramming, are recoverable; a recoverable module is not covered
under the provisions of the warranty.
This service bulletin covers items that may cause this condition, a process to restart the flash
procedure, and miscellaneous information that will help prevent needless replacement of control
modules.
GENERAL: Flash Reprogramming is only authorized by a specific SERVICE BULLETIN, or
RECALL.
Review the entire Service Bulletin/Recall prior to performing a flash reprogramming update. Often
other parts may need to be serviced, replaced, or tested, prior to flash reprogramming, and ARE
REQUIRED as part of completing the Service Bulletin/Recall.
When flashing a Powertrain Control Module (PCM) or Transmission Control Module (TCM) there
are other legal requirements with labeling issues that are included in those service bulletins.
Other non-emission related modules, such as instrument clusters and Body Control Modules
(BCMs) do not require labels.
FLASH REPROGRAMMING SEQUENCE OF EVENTS
The process of flash reprogramming is similar to flashing the BIOS on a Personal Computer.
Interruptions, voltage problems, and a variety of other outside interactions can potentially interfere
with the process. This document seeks to provide information to minimize problems associated
with vehicle control module flash reprogramming. The description that follows is for most PCMs
and some TCMs. Other modules use different initiation procedures.
The process starts by selecting an update from the TechCONNECT Client or ISIS and then
"loading" that update into the DRBIII(R). Once the flash reprogramming update is loaded into the
DRBIII(R), and before the flash reprogramming begins, the DRBIII(R) verifies that the update
loaded from the TechCONNECT Client or ISIS is the proper update for the module. This is done
using part number supersedence. This verification occurs only if an update is required, available
(on the TechCONNECT Client or ISIS) and has been selected for programming.
^ The module is then placed into "Boot Strap" programming mode by the DRBIII(R). This module
mode gives the DRBIII(R) permission and the ability to proceed with the flash reprogramming
session.
^ Next, the current part number, which resides in the module's flash memory, is stored in a "Safe
Memory" location within the module. This memory location is not affected by flash memory erasure
and reprogramming, which are to follow.
^ Once the part number is safely stored, the flash memory in the control module is erased. From
this point forward any interruption in the flash process,
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4527
will result in a Non-Responsive module (NR). A NR module is a module that is either partially
erased or partially programmed.
^ After erasure, the actual reprogramming procedure starts, and the update software is
programmed into the flash memory within the module.
^ When reprogramming is completed, the flash memory is verified through an internal process in
the DRBIII(R) using a "Check Sum". This value is compared against another value that represents
what should be in memory and when matched, verifies successful reprogramming.
^ Next, a DRBIII(R) prompt is displayed instructing that the ignition switch be turned OFF. The
module exits the "Boot Strap" mode when the switch is turned off.
^ After a slight pause, the DRBIII(R) will prompt for the ignition switch to be turned ON. The
DRBIII(R) then reads the new part number in flash memory (along with a new computer program
the new part number is placed into the module's memory). If the new part number matches the
expected part number, the flash reprogramming session has completed successfully.
SOFTWARE VERSIONS MUST BE CURRENT
Before attempting a flash reprogramming session using the TechCONNECT Client, make sure you
have the most current DRBIII(R) software installed.
To verify whether your DRBIII(R) software is current, check the upper right-hand corner of the
TechCONNECT Client screen for DRBIII(R) Available Version, DRBIII(R) Current Version.
Often, because of multiple DRBIII(R)s in the shop, not all will get updated on a timely manner. The
installed DRBIII(R) software version can generally be found at the bottom center of most screens.
Alternately the version can be checked by pressing 6, 2, 5 from the DRBIII(R) Main Menu and
comparing it to what is available from a current TechCONNECT Client as described above.
If the TechCONNECT Client is current and the DRBIII(R) is not, it may be due to the fact that the
TechCONNECT Client does not force DRBIII(R) updates for "minor" revisions. Changes and new
support are added to the Vehicle Flash application on "minor" revisions on a regular basis. This is
why your TechCONNECT Client and DRBIII(R) must have the LATEST software revisions
installed.
DO NOT PASS on the option for updating to a "minor" revision!
Major updates require the DRBIII(R) to be updated prior to allowing any flash programming.
DRBIII(R) CABLES
A NEW DRBIII(R) cable was released as an Essential Service Tool! CH7000A - 8 ft.
Cable, DRBIII(R) to OBDII (J1962) DLC Connector.
CH7000A is the required cable for ALL flash reprogramming. The older CH7000 cable can be used
for diagnostics ONLY. One (1) cable was shipped to all dealerships. Easily identified, the correct
cable has a RED connector, which plugs into the DRBIII(R).
The cable modification enhances the DRBIII(R) communication capabilities when dealing with the
flash requirements of certain controllers/ECUs affected in part by the recent changes in DLC
connector configurations.
The new cable is required for ALL flash reprogramming sessions, and can be used wherever the
previous CH700017001 cables were used.
While not recommended for flash reprogramming usage, if you require a longer cable, there is also
a 12-foot cable released under pin CH7001A
The production of the previous CH700017001 cables has ceased. All orders placed will be
superseded to part number CH7000A/CH7001A.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4528
NOTE:
Consider all cables wear items. Always inspect for worn, damaged cables, connectors that are
damaged or do not lock securely, and all mating connections including checking for corrosion on
the pins. REPLACE ALL suspect cables. Do not use worn or damaged cables when flash
reprogramming.
Failure to use the new cable or to use a damaged cable often results in failed flash reprogramming
sessions.
The 2 door Sebring, Stratus, and Avenger coupes (supplied by MMC) generally use the CH7O1O
cable (Pre-OBDII MMC vehicles will use the CH7005 cable).
TechCONNECT CABLE (GPIB)
Replace any suspect GPIB cable.
The GPIB cable provides the connection between TechCONNECT Client and the DRBIII(R).
This cable is used by the TechCONNECT Client for vehicle part number reads and to send update
files to the DRBIII(R).
Inspect this cable for loose connections, damaged connectors or terminals, and wear and tear. If
this cable becomes disconnected during a flash session, you may have to reload the update file
that you selected on the TechCONNECT Client.
TROUBLESHOOTING CONNECTIVITY OF THE DRBIII(R) UNIT TO THE TechCONNECT
APPLICATION.
1. Turn-on the power to the DRBIII(R) unit.
2. Select option 2 "Connect to TechCONNECT" and press Enter.
3. Attach the male mini D-shell amphenol GPIB connector of the new DRBIII(R) cable (part number
CH7035B) to the DRBIII(R) unit.
4. Insure that the larger female D-shell amphenol GPIB connector of the new DRBIII(R) cable is
properly attached to the male D-shell amphenol GPIB connector on the GPIB-USB-B protocol
converter, (part number CHGPIB-B).
5. Attach the USB cable from the GPIB-USB-B protocol converter to one of the USB ports on the
rear panel of the client CPU.
6. When the cable is attached to the USB port of the CPU for the first time, Windows 2000 will
detect the device and install software for it. Please wait for 25-30 seconds to complete the
installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4529
ISIS NULL MODEM CABLE
Replace any suspect null modem cables.
International (ISIS), a PC-based CD program similar to TechCONNECT Client uses a null modem
cable for vehicle part number reads and to send update files to the DRBIII(R). Inspect this cable for
loose connections, damaged connectors or terminals, and wear and tear. If this cable becomes
disconnected during a flash download session, you will have to reload the update file or files.
GENERAL NOTES FOR CABLES AND VEHICLE CONNECTIONS
Consider ALL cables to be wear items.
Many successful dealers have dedicated cables devoted to "Flash ONLY".
Always have spare CH7000A, CH7010 and CH2002 GPIB or null modem cables available.
Inspect vehicle diagnostic connectors for potential problems that might cause communication
interruptions.
There are now clip repair kits available through teamPSE to replace the retaining clips for two of
these cables. To protect the DRBIII(R) from internal damage, the clips are designed to fail at above
25 lbs. of axial force. Kits are described in the table.
It is a good practice to discard cables that have damage to the pins, cuts, corrosion, or general
damage beyond the retaining clips.
ST22 SEBRING STRATUS 2 DOOR COUPES (2001-2005)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4530
These vehicles use MMC based modules. The CH8432 Supplemental Reprogramming Tool (SRT)
was shipped as a 2001 Essential Tool. The flash reprogramming update files will be downloaded
from TechCONNECT Client to the SRT for flash reprogramming sessions on these vehicles. Users
should closely follow the instructions that come with the tool. If the tool has not been initialized,
there is a known condition where it may take up to 5 or more attempts for it to fully initialize and
become functional.
NOTE:
Once it has successfully flashed, it is initialized and no further action is required.
PREPARING TO FLASH
It is highly recommended that a sign, or other process, be used that notifies other users that a
FLASH SESSION IS IN-PROGRESS and must NOT be interrupted. Interrupting some flash
reprogramming sessions at critical junctures can render a module inoperative. Another user may
not realize that a flash session is in-progress and may disturb or disconnect the DRBIII(R) or do
something on the vehicle that could interrupt the flash process.
Before starting the flash session, read, record and erase all DTCs found on the vehicle.
Also "Cold Boot" the DRBIII(R) and download the flash since this will erase the flash file from the
DRBIII(R) memory. (To "Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the
same time. Then press "F4").
Be sure to arrange the TechCONNECT and DRBIII(R) so that no cables are stretched across an
area where someone might trip over or kick a cable. When setting up your DRBIII(R), insure that it
rests on a surface where it will not fall or be bumped during reprogramming e.g.: DRBIII's have
been known to be swept off vehicle windshields by accident when a user bumps the wiper switch).
Check User settings on the DRBIII(R). From the DRBIII(R) Main menu, press 6,1 and check to
make sure item 1. Echo on PC is set to OFF. On occasion, when Echo on PC is set to ON, flash
reprogramming errors may occur.
VEHICLE BATTERY VOLTAGE
The flash programming procedure puts a load on the electrical system that may last from five to
twenty minutes depending on the particular flash reprogramming update. Connect a battery
charger to the vehicle. Set the charger to as close to 14 volts as possible. If the charger has a
timer, set it for 30 minutes BEFORE starting a flash reprogramming session. This will help to
prevent unwanted resets by either the DRBIII(R) and/or the vehicle module that are caused by
voltage fluctuations.
Alternately, as a bare minimum, use a "Battery Jump Box" when a battery charger is unavailable to
ensure adequate and stable system voltages on the module being flash reprogrammed.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Connected/Disconnected Flash Mode Using TechCONNECT
CONNECTED MODE FLASHING USING TechCONNECT
NOTE:
Capable but not recommended.
In this mode, the DRBIII(R) remains connected to the TechCONNECT Client and the vehicle
throughout the flash session. The DRBIII(R) is connected to the TechCONNECT Client using the
GPIB (CH7035) cable and to the vehicle using the vehicle I/O cable (the CH7000A for most
vehicles).
This mode is useful when the TechCONNECT Client is next to the vehicle being flashed.
Another advantage of this mode is that you are able to determine all available flash updates for the
vehicle you are connected to by clicking on the "Read Part Number(s) From Vehicle" button.
Again, it is important that other users do not attempt to reboot or move the TechCONNECT Client
while a flash update is in-progress.
The reprogramming procedure of this mode is initiated by selecting the controller option and
clicking "Download/Update" button on the TechCONNECT client.
DISCONNECTED FLASH MODE
NOTE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4531
This is the preferred method.
This mode allows a user to flash a vehicle without being connected to the TechCONNECT Client.
This is a popular mode for flashing in a remote area of the service garage or in a back lot.
Before you attempt to use this mode, you must configure the DRBIII(R) for the desired update(s).
To do this, you must connect the DRBIII(R) to the TechCONNECT Client using the GPIB cable and
the CH7025 cable. It is not necessary to be connected to a vehicle. The GPIB (CH7035) cable will
be used to communicate with the TechCONNECT Client (for update file downloading) while the
CH7025 cable is used to provide power to the DRBIII(R).
After making the above connections, you are able to select one or more updates that you want to
perform. These selections are made by highlighting the desired updates and then clicking on the
"Download/Update" button by selecting the DRBIII(R) option on the TechCONNECT client.
Obviously, the DRBIII(R) does not have unlimited memory. If the file size of the selected updates
exceeds 948 KB, the "DRB Space Used" indicator (at the bottom-center of the TechCONNECT
Client screen) will change color from GREEN to RED. At this point you must de-select entries until
the indicator changes color to GREEN again.
When the updates have finished downloading, you may disconnect from the TechCONNECT Client
and take the DRBIII(R) to wherever the vehicle is located. The updates will remain in DRBIII(R)
memory for 8 hours while the DRBIII(R) is without power. If the DRBIII(R) is powered up for several
minutes before the 8 hour time period has expired, the update files will remain on the DRBIII(R) for
another 8 hours without power.
To start the actual flash process, after connecting to the vehicle in Disconnected Mode, you must
press "7 - Vehicle Flash" from the Main Menu on the DRBIII(R). Step by step instruction will follow
on the DRBIII(R) display. As with Connected Flash Mode, take the necessary precautions to insure
that others are aware of the flash session and that nothing disturbs the vehicle, DRBIII(R), or
cabling while performing the flash. Remember to use a battery charger set to 14 volts or a "battery
jump box".
Pay Attention While Performing Flash Reprogram Procedures
PAY ATTENTION WHILE PERFORMING FLASH REPROGRAMMING PROCEDURES
Before downloading the flash files, double check to see if the files that you have selected are the
appropriate ones for that vehicle. Don't forget about the "Read Part Numbers From Vehicle" option
on TechCONNECT Client, this can be of great assistance when trying to flash a module. If the files
selected don't download on the first attempt, try again.
The technician should NOT leave the vehicle when flash reprogramming a module.
Again, check to make sure that all cable connections are secure and that the DRBIII(R) rests on a
stable surface. If you are using a battery charger, insure that the settings and charging times are
correct and that the battery post clamps are securely fastened.
Read, record, and erase all DTCs found on the vehicle. Read and record the module type and part
number from the module that is to be flash reprogrammed.
Some control modules are not "abort-recovery" capable. When this is true, the scan tool will
indicate so by displaying a WARNING message prior to the start of reprogramming. For these
modules it is especially important that all precautions and procedures, outlined here, are carefully
followed.
Pay special attention to DRBIII(R) screen directions relating to key cycles. Missing a "Key ON" or
"Key OFF" can cause the module to have to be reflashed again. Due to the variety of module types
and vehicle options, you can't always anticipate key prompts, so be alert and ready to respond to
DRBIII(R) instructions.
Some screens will also instruct that certain modules, connectors or fuses be disconnected or pulled
prior to the start of reprogramming and re-installed immediately after completion. Be careful not to
anticipate the steps or order of operations for reprogramming any vehicle modules. Because of the
many possible changes that occur with each new release of scan tool software, always allow the
TSB/Recall and scan tool instructions to be your guide while performing flash reprogramming.
Flash reprogramming sessions usually range from 5 to 20 minutes. If the flash session has not
completed within 25 minutes after starting a flash reprogramming update, an error has most likely
occurred (Record the message that appears on the screen when a failure occurs). If this is the
case, or if you know that the flash process was interrupted, cycle the ignition key (OFF to the
locked position, then back ON). Reset the DRBIII(R) (power down for 4 seconds and then power
up) before attempting to restart the flash process. If the module still won't respond, turn the ignition
key off, disconnect the module from the vehicle for 2 minutes, reconnect the module, turn the
ignition key to run and try to restart the flash process again.
Regardless of what mode that you are in (Connected Flash or Disconnected Flash), if you have
tried twice (2 times) unsuccessfully to do a flash recovery and ALL DRBIII(R) instructions were
followed, perform the following:
^ Cold boot the DRBIII(R). This resets memory and removes all update files from the DRBIII(R).
(Push MORE and YES buttons at the same time, then press F4).
^ Reload the flash update file from the TechCONNECT Client.
^ If it fails to complete in the connected mode, first reboot the TechCONNECT Client before
re-attempting the flash download to the DRBIII(R).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4532
^ Proceed to reflash the module.
On vehicles that have multiple flash updates available, always complete and verify each flash
update before attempting the next one.
After all flash reprogramming is completed, read and erase all DTCs in all modules on the vehicle.
A variety of DTCs may be set, which are usually related to a loss of communication with the
module(s) being reprogrammed.
Verify the update by reading the new part number using the DRBIII(R). A good double check is to
read the part number using DRBIII(R) stand alone.
At times, other modules, wired in parallel, to the DLC connector have prevented flash
reprogramming sessions to be successful. After the failed attempt, review the appropriate wiring
diagram for the vehicle you are flash reprogramming and, with the key "OFF"; disconnect the other
modules and retry the flash. Complete the flash, turn the key "OFF" and reconnect any modules
that were disconnected. Refer to the "Programmable Modules" section later in this document for
more information.
Error Messages
ERROR MESSAGES
Block Echo/Compare Errors
Block Echo and Block Compare errors are often caused by voltage fluctuations, faulty I/O cables
(CH7OOOA, CH7005, CH7010) or faulty communication connections at the diagnostic connector.
Inspect for these conditions and review the sections on Vehicle Battery Voltage and Cable
recommendations.
Checksum Errors
Checksum Errors are generally caused by corrupt flash update files, which can be caused by
DRBIII(R) memory problems. If the DRBIII(R) has been without power for more than 8 hours, the
update files and system memory could be in a corrupted state. "Cold Boot" the DRBIII(R). (To
"Cold Boot", press the MORE and YES buttons on the DRBIII(R), at the same time. Then press
"F4"). Reload the flash update file(s) from the TechCONNECT CLIENT. If it fails to complete in the
connected mode, first reboot the TechCONNECT Client before re-attempting the flash download to
the DRBIII(R). Then re-attempt the flash reprogramming process.
Enhanced and Original Abort Recovery
ENHANCED ABORT RECOVERY
Interruptions in the flash process are one of the main reasons for failed flash sessions and
non-responsive (NR) modules. Interrupting the flash process after the erase phase has started will
leave the control module in a non-functional state.
Generally, but not always, NR modules may be recovered successfully.
Briefly, abort recovery is the process used to get a NR module back to a fully functional state with
the latest software update. The technician should be familiar with the other sections in this
document and follow all DRBIII(R) user prompts carefully.
There are two methods for abort-recovery. The newer method is called "Enhanced Abort
Recovery". This is the preferred method since the original method takes several minutes longer
and requires the correct selection of module type from a list of possible PCM's or TCM's.
Starting with Release 60.1, a new useful feature was added to the flash reprogramming application
for Engine and Transmission control modules. The DRBIII(R) "writes" the YME and Controller Type
information to a "Safe Memory" location. This method allows for rapid recovery of the module part
number and minimizes errors that could otherwise be made by selecting the wrong controller type.
It also assumes that the user will attempt abort recovery for a failed flash attempt before moving to
another vehicle with the same DRBIII(R). If you need to move to another vehicle for flash
reprogramming you must erase the saved recovery information in order to successfully perform
flash reprogramming. Be careful to match the YME information displayed on the enhanced abort
recovery screen with the vehicle and module that you are attempting to recover. If you use the
recovery file on a different vehicle and module you could damage the module.
The recovery information will be displayed on your DRBIII(R), at the start of a flash session, only if
you previously encountered a problem that prevented a flash session from completing normally. If
your prior flash session was successful, the DRBIII(R) automatically erases the recovery file so that
the flash application will not show any recovery information at the start of your next flash session.
Enhanced abort recovery features:
^ Reduces the amount of time for the Module ID process.
^ Lowers the risk of possible user mistakes by presenting the user the Year, Model, Engine, and
Controller Type.
^ Currently only applicable to Engine and Transmission flash reprogramming.
^ The enhanced abort recovery file will only be erased upon a successful flash or manually by the
user.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4533
^ Cold booting (simultaneously pushing MORE & YES, then F4) the DRBIII(R) will not erase the
enhanced abort recovery file, but cold booting the DRBIII(R) will still erase the flash file so it can be
reloaded.
^ The user has a choice, at the start of a flash session, whether or not to use the enhanced abort
recovery feature. If the user chooses to erase the recovery file, then the DRBIII(R) will use the
original method of abort recovery.
^ Cycling the ignition key, when prompted by the DRBIII(R), is still necessary to put the controller
into bootstrap (reprogramming) mode.
ORIGINAL ABORT RECOVERY
If the choice is made to use the original method of abort recovery, a NR module is not always able
to provide the DRBIII with ID information. In this case the technician must enter this when prompted
by the DRBIII(R). Be patient when performing this process. If the module does not respond to
standard diagnostic requests, the DRBIII(R) may take several minutes before it determines that the
engine module is in a NR state. At this point, the DRBIII(R) displays the prompt "Could not
determine engine controller type. Please select from list" along with a list of possible controller
types (if the DRBIII(R) is attempting to identify a TCM, the prompt will say "trans" instead of
"engine" and list the possible trans controller types). Because of module variations, it is important
to correctly identify the PCM/TCM type so that the correct flash procedure is used. Failure to do
this will cause further problems and may damage the module. Tables are provided below to help
identify the proper module type to select. These tables correctly identify the modules that were on
the vehicles when they were built. However, some vehicles will have module types which were
superseded to a new type when a replacement part was installed (ie: EATX4 modules replaced
with an EATX4A). Correctly identify these modules using DRBIII(R) Standalone prior to attempting
flash reprogramming.
NOTE:
When instructed to turn the key to the LOCKED position, be sure that the key is not just turned to
the OFF position. The key must be rotated to the point at which it can be removed from the ignition
switch. On most vehicles the switch is on the steering column and at this position the steering
column is LOCKED. When instructed to turn the key to the RUN position, be careful not to turn the
key past this position which may engage the starter motor. This creates electrical noise which
interferes with the flash process.
General Steps for Abort Recovery
1. Review all Tips and Techniques before continuing. Pay special attention to the section on
Preparing to Flash a controller and to the Programmable Modules section.
2. Cycle the vehicle's ignition key to the LOCKED position and back to the RUN position.
3. Reset the DRBIII(R) by disconnecting the vehicle cable from the DRBIII(R) for 4 seconds and
then reconnecting the cable.
4. Depending on where the flash session was aborted, the DRBIII(R) may require that the
technician identify the control module type that was being flash reprogrammed. Use the PCM/TCM
configuration table below as a guide. This step is not necessary if using the enhanced abort
recovery method.
5. After selecting the proper control module type or choosing enhanced abort recovery, follow the
prompts that are displayed on the DRBIII(R).
NOTE:
If an error message is displayed at this point, an incorrect module type was most likely selected. If
this occurs, start the process over.
6. If the recovery process is unsuccessful, perform the following:
a. Review the TSB/Recall notice (authorizing the flash update) and all Tips and Techniques in this
document.
b. Reboot/Restart the TechCONNECT Client.
c. "Cold Boot" the DRBIII(R). (Press the MORE and YES buttons on the DRBIII(R) at the same
time, then press F4).
d. Start this process over from item # 1. If using Disconnected Mode, the flash update will have to
be reloaded from the TechCONNECT Client or ISIS DVD.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4534
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4535
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4536
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4537
Programmable Modules
The following pages list the various modules that have flash reprogramming capability. It does not
mean that a flash is currently available. What will be described are the module types and
variations, followed by items to note, and finally, abort recovery specifics if applicable.
Powertrain Modules - Engine and Transmission
ENGINE - POWERTRAIN CONTROL MODULE (PCM)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4538
There are a variety of Engine (PCM) modules that are flash reprogrammable. Suggestions that are
somewhat unique to each type will have comments. Prior to reprogramming a PCM, retrieve the
module information and module type using your DRBII I®. PCM information is used by many
modules. Be sure to check DIG's before and after performing all flash reprogramming event.
The DTC's associated with flash reprogramming generally relate to "lack of communication" with
the other modules during the reprogramming session.
SBEC
Types:
SBEC, SBEC 2, SBEC 3, SBEC 3+, SBEC 3A, SBEC 3A+, and SBEC 3B
NOTE:
During recovery, if the DRBIII® is not seeing the key off, you may need to remove power (B+) to
PCM by removing fuse(s) or disconnecting the PCM. When DRBIII® states to turn key ON,
reconnect fuse or harness connection.
Abort Recovery Specifics:
^ Follow instructions on the DRBIII® for the module type. See table above.
^ Some SBEC 3A, SBEC 3A+ AND SBEC 3B may be in a state where they can not correctly
identify a key cycle. In this case a Modified Key Cycle routine is required.
This state is present when the following message is displayed on the DRBIII(R): "Can not read Part
Number. Did not see Key On or PCM/TCM Controller may not be flashable". When this occurs
restart the flash session and when prompted to turn the ignition key to the LOCKED position, pull
the fuse(s) that supply battery power to the module instead. When prompted to turn the key to the
RUN position, replace the battery supply fuse(s) instead.
JTEC
Types:
^ JTEC, JTEC+
NOTE:
Viper ALL - Roll down windows especially Coupes before attempting a flash.
NOTE:
1999 WJ JTEC with Speed Proportional Steering module. Disconnect before and reconnect after
the PCM flash reprogramming session. Also see Transmission.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
NGC Types:
^ NGC 1, NGC 2, and NGC 3
NOTE:
There are derivatives of NGC 3 that will be significant when reprogramming and or testing. NGC
modules use one of the longest time spans for flash reprogramming (approximately 15 minutes).
The NGCI and NGC3 controllers incorporate both an engine as well as a transmission controller in
a common package. The NGC2 controller incorporates the engine controller and an Electronic
Throttle Control (ETC) module in place of the TCM. All NGC controllers can be visually identified by
noting its four (4) wiring connectors. On manual transmission applications and the NGC2, only 3
connectors may be populated with pins.
NOTE:
On certain vehicles, the ABS CAB module connector MUST be disconnected prior to performing
this Repair Procedure. The CAB module and the PCM are connected at the same diagnostic
connector pin (Pin # 9). Turn ignition switch to the OFF position, disconnect the CAB module
connector, and reprogram the PCM per the Repair Procedure. When reprogramming is complete
turn the ignition switch to the OFF position, connect the CAB module connector, and then check for
DTC's. If the PCM becomes "locked" during reprogramming because the ABS CAB module
connector was not disconnected, then the PCM may be recovered by following the procedure in
this NOTE.
Abort Recovery Specifics:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4539
^ Follow DRBIII(R) prompts carefully.
^ Power down the DRBIII(R) then cycle ignition before powering up the DRBIII(R) to attempt the
flash.
CUMMINS
Types:
^ CM551 and CM84x series
NOTE:
Cummins flash reprogrammable PCMs are used on 1998.5 and newer Dodge Trucks.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. Model Year 2000 and earlier vehicles have one Engine
Control Fuse to pull when prompted by the DRBIII(R). Model Year 2001 and later have two Engine
Control Fuses (one 20 Amp and one 30 Amp) to pull when prompted by the DRBIII(R). The fuse(s)
are located in the PDC and need to be pulled/removed, when prompted, for at least 10 seconds.
SIEMENS
Types:
^ SIM-70
NOTE:
The SIM-70 is currently used on BUX PL and PG vehicles with a 1.6L ONLY. Abort Recovery
Specifics:
Follow DRBIII(R) prompts carefully.
BOSCH
Types:
^ EDC15V, EDC15-C5, and EDC16
NOTE:
While there have been other Bosch modules, the EDC15V is not flash reprogrammable.
Transmission controllers are usually flashed on the vehicle (since 1996).
Technicians may set the pinion factor on "NEW" modules either before or after flash
reprogramming. Suggestions follow.
After flash reprogramming and before returning the vehicle to the customer, always perform a
"QuickLearn" to the TCM.
EATX
Types:
^ EATX, EATX 2, EATX 3, EATX 3A, EATX 3B, EATX 4, and EATX 4A
NOTE:
Table shows which TCM was installed "as-built". Often TCMs are superseded by parts and or a
service bulletin.
Abort Recovery Specifics:
^ 1999 - 2000 WJ and 2000 AN/DN using 4.7L engines the service replacement EATX4A part
numbers 56041814AD and 56028227AH currently display a P/N read failed error after the flash is
completed during PIN verification. This DOES NOT mean the flash failed. Check for the part
number using DRBIII(R) in standalone mode. This exists only for the service replacement modules
listed above. Flash reprogramming for OE modules flash and read the part number correctly.
Follow DRBIII(R) prompts carefully.
NGC
Types:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4540
^ NGC1, NGC2, NGC3
NOTE:
The NGC I1and NGC 3 have the EATX/XCORE and Engine modules combined. NGC 2 does not.
Vehicles with automatic transmissions using NGC2 will use an EATX4A.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
^ 2002 DR, 2002.5 DN, 2003 AN/DN and later with NGC have shown that in some instances the
CAB controller may need to be disconnected when attempting to flash the NGC controller. (This
should only be performed if an error occurs at the very beginning of the TCM flash portion.)
SIEMENS
Types:
^ EG552
NOTE:
EGS52 is used with the A580 automatic transmission WG Grand Cherokees with a 2.7L diesel
engine (BUX), ZH Crossfire and VA Sprinter.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
JTEC
Types:
^ JTEC,JTEC+
NOTE:
Except for the 45RFE, 545RFE, and AW4 automatic transmissions, the JTEC controller also
provides transmission control functions on Dodge trucks and Jeep vehicles. Additionally, they are
used on some Cummins equipped Dodge trucks with manual and automatic transmissions.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
PRE 1996 EATX TRANSMISSION CONTROL MODULES
Prior to 1996 there was not a vehicle SCI communication wire going to the FWD EATX controller
only to the PCM. Those vehicle TCMs only communicate to the DRBIII(R) using CCD
communications.
For these FWD vehicles, use the CH5500 kit and CH7025 DIN cable when connecting those
modules to the DRBIII(R) vehicle connector.
For 1992-1993 vehicles, the TCM modules were upgraded to MY1995 software. Because of this
you will need to use the Yellow SuperCard2, CH8361,to set pinion factor or when using a "new"
(superseded) TCM from parts as only the SuperCard2 properly sets the pinion factor on these
updated modules.
Additionally, when flashing or installing P/Ns 4796121, 4796122, 4796123, or 4796124.
The wire from cavity 49 must be removed from the TCM connector, refer to service bulletin
18-24-95.
Types:
^ TCCM
NOTE:
These modules are found on AN, DN, and DR trucks.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4541
NON-POWERTRAIN CONTROL MODULES
BODY CONTROL MODULE (BCM)
Types:
^ BCM
NOTE:
Body control modules are found on passenger vehicles.
NOTE:
The following vehicle BCMs support flash reprogramming: CS, JR, KJ, LH, RS, WJ, and ZB.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
^ BUX ONLY for 2001 JR - Compass/Mini Trip (BCM) Flash - Use special international release
software version 52.25
^ 2001 LH - there is NO abort recovery available for the BCM.
CENTRAL TIMER MODULE (CTM)
Types:
^ CTM
NOTE:
CTMs are found on: AB, AN, DN, BR, and BE trucks.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
ELECTRONIC VEHICLE INFORMATION CENTER (EVIC)
Types:
^ EVIC
NOTE:
02-03 LH & WJ, and 03-04 KJ
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
FRONT CONTROL MODULE (FCM)
Types:
^ FCM
NOTE:
Front control modules are found on CS, DR, RG, and RS vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
INTEGRATED POWER MODULE (IPM)
Types:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4542
^ 1PM
NOTE:
Integrated power modules are found on CS, DR, RG, and RS vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
POWER LIFT GATE (PLG)
Types:
^ PLC
NOTE:
Power liftgate modules are found on CS and RS.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. PASSENGER SLIDING DOOR MODULE (PSDM)
Types:
^ PSDM
NOTE:
Passenger power sliding door modules are found on RG and RS vehicles. Abort Recovery
Specifics:
^ Follow DRBIII(R) prompts carefully. DRIVER SLIDING DOOR MODULE (DSDM)
Types:
^ DSDM
NOTE:
Driver power sliding door modules are found on RG and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
NOTE:
When flashing a vehicle that is equipped with both Passenger and Driver Power Sliding Doors, you
must Reboot the DRBIII(R) and cycle the ignition key before flashing the next door module.
DRIVER DOOR MODULE (DDM)
Types:
^ DDM
NOTE:
Driver Door Module is found on the CS and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. PASSENGER DOOR MODULE (PDM)
Types:
^ PDM
NOTE:
Passenger Door Module is found on the CS and RS vehicles. Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
CLUSTERS/MECHANICAL INSTRUMENT CLUSTER (MIC)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4543
Types:
^ MICs, eMICs
NOTE:
MICs that have flash reprogramming are on the following vehicles: DR, JR, KJ, PL, PT, WJ, ZB
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully. In certain cases, you will be asked to cycle the ignition key
and pull a specific fuse.
^ The DRBIII(R) may power down during the procedure with some modules. This is NORMAL and
is explained in the user prompts displayed during abort-recovery. Take the time to read and
understand the instructions before proceeding.
ALARM REMOTE KEYLESS ENTRY MODULE (ARKEM)
Types:
^ ARKEM
NOTE:
Arkem modules are found on PL and PT vehicles. There are up to and after modules.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
CLIMATE CONTROL (ATC, HVAC)
Types:
^ HVAC, ATC, MTC
NOTE:
Generally, reprogramming for these modules is done using the standalone application rather than
the Vehicle Flash application.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully.
ADJUSTABLE PEDAL MODULE (APM)
Types:
^ APM
NOTE:
Found on CS, RS, and WJ vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
RAIN SENSOR MODULE (RSM)
Types:
^ RSM
NOTE:RSM modules are found on CS, RS, and WJ vehicles.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
18-037-05 > Oct > 05 > Engine Controls - Flash Programming Failure Recovery > Page 4544
INTRUSION TRANSCEIVER MODULE (ITM)
Types:
^ ITM
^ Updates for this module, to version 7.05 have involved a coordinated BCM flash update. See the
TSB for important instructions.
NOTE:
ITM modules are found on WJ (BUX) and KJ (BUX) vehicles.
Abort Recovery Specifics:
^ Follow DRBIII® prompts carefully.
SUPPLEMENTAL RESTRAINT SYSTEMS (SRS) - AIRBAGS, ETC.
Types:
^ SRS, ORC
NOTE:
While used on most vehicles, only CS, JR, LH, PT, RS, and WJ vehicles have the potential to
support flash updates.
Abort Recovery Specifics:
^ Follow DRBIII(R) prompts carefully.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM
Technical Service Bulletin # 771 Date: 980501
Campaign - Radiator Fan Relay and PCM
No. 771
May, 1998
To: All Dodge and Chrysler-Plymouth Dealers
Subject: Customer Satisfaction Notification # 771 -- Radiator Fan Relay and Reprogram Powertrain
Control Module
Models: 1998 Model Year Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand
Voyager; and Chrysler Town & Country (NS) Vehicles Equipped With a 2.4L, 3.3L or 3.8L Engine
("B", "G","R" or "L" in the 8th VIN Position) Built Through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
Position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN Position)
The radiator fan relay on about 150,000 of the above listed vehicles, may not turn on the radiator
cooling fans. This may cause the engine to overheat. To correct this condition, the radiator fan
relay must be replaced and the Powertrain Control Module (PCM) must be reprogrammed
(flashed).
Dealer Notification & Vehicle List
All dealers will receive a copy of this dealer notification letter by first class mail. Each dealer to
whom involved vehicles were invoiced (or the current dealer at the same street address) will
receive a list of their involved vehicles. The Vehicle List is arranged in Vehicle Identification
Number (VIN) sequence. Owners known to Chrysler are also listed. The lists are for dealer
reference in arranging for service of involved vehicles.
DIAL System Functions 53 and VIP
All involved vehicles will be entered to DIAL System Functions 53 and VIP at the time of notification
mailing for dealer inquiry as needed.
Function 53 provides involved dealers with an updated VIN list of incomplete vehicles. The
customer name, address and phone number is listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "ORD771".
Parts
IMPORTANT:
A quantity of parts will be distributed initially and billed to all involved dealers. This quantity will
cover a portion of the total vehicles involved. Additional parts may be ordered as needed to support
customer demand.
Each involved dealer, to whom vehicles in the notification were invoiced (or the current dealer at
the same street address), will receive enough Radiator Fan Relay Packages, PN CEP07710, to
service about 25% of those vehicles.
Each parts package contains the following components:
Quantity Description
1 Radiator Fan Relay
2 Screws
1 Label, Authorized Software Update
1 Label Authorized Modifications
Owner Notification and Service Scheduling
All involved vehicle owners known to Chrysler are being notified of the service requirement by first
class mail. They are requested to schedule a service appointment with their dealer. A copy of the
owner notification letter is included.
Enclosed with each owner notification is an Owner Notification Form. The involved vehicle and
notification are identified on the form for owner or dealer reference as needed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4549
Completion Reporting and Reimbursement
Claims for vehicles which have been serviced must be submitted on the DIAL System. Claims
submitted will be used by Chrysler to record notification service completions and provide dealer
payments.
Use one of the following labor operation numbers and time allowances:
Labor Operation Time
Number Allowance
Replace radiator fan relay and check PCM 08771182 0.3 hours
Replace radiator fan relay and reprogram PCM 08771183 0.7 hours
Add the cost of the parts package plus applicable dealer allowance to your claim.
Note:
See the Warranty Administration Manual, Recall Claim Processing Section for complete claim
processing instructions.
Parts Return
Not required.
Vehicle Not Available
If a vehicle is not available for service for a known reason, let us know by filling out the
pre-addressed Vehicle Disposition Form portion of the Owner Notification Form or describe the
reason on a postcard and mail to:
Chrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan 48326-2757
Following the above procedures will expedite the processing of your claim.
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
A. Replace Radiator Fan Relay
1. With the ignition key in the OFF position, disconnect the battery.
Note:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
2. Remove the two (2) screws that attach the air inlet resonator to the upper radiator support.
3. Disconnect the upper and lower air inlet hoses from the resonator and remove the resonator.
4. Remove the air cleaner housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4550
5. Locate the radiator cooling fan relay on the left front inner frame rail just behind the radiator
(Figure 1).
6. Disconnect the radiator fan relay wiring connector.
7. Remove the radiator fan relay. Discard the relay and the attaching screws.
8. Install the new radiator fan relay using the supplied screws. Tighten the screws to 35 in-lbs (4
N.m).
CAUTION:
Do not over torque screws. To ensure heat transfer and proper operation, the new radiator fan
relay must be installed using both of the provided screws.
9. Connect the radiator fan relay electrical connector. Slide the red latch to the locked position.
10. Install the air cleaner housing.
11. Install the resonator assembly and connect the upper and lower air inlet hoses.
12. Install the resonator to upper radiator support screws. Tighten the screws securely.
13. Connect the negative battery cable.
B. Reprogram the PCM
1. Connect the MDS (Mopar Diagnostic System) and the DRB III(R) (Scan Tool) to the vehicle and
power them up.
NOTE:
The Mopar Diagnostic System is required to perform the PCM flash. The system must be operating
with RELEASE 21 or higher and TIL CD RELEASE 1157 or higher must be installed.
2. Use the arrow keys and select # 2 -- MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTICS MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the PCM.
7. The MDS will display the part number of the PCM on the vehicle and the appropriate
replacement part number then press NEXT MENU to begin programming.
NOTE:
If the PCM on the vehicle has already been updated or reprogrammed, a NO UPDATES
AVAILABLE message will be displayed. Verify that the part number of the PCM (or previously
installed authorized software update label) matches the part number displayed on the MDS and
then continue with Section D.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4551
C. Install Authorized Software Update Label
1. Type or print (with a ball point pen) the necessary information on the "Authorized Software
Update" label (Figure 2) and attach it to the PCM. Cover the label with the clear plastic portion of
the label.
D. Install the Authorized Modification Label
1. Type or print (with a ball point pen) the following information on the Authorized Modification
Label and attach the label near the VECI label (Figure 3).
Dealer Service Instructions
IMPORTANT
DEALER SERVICE INSTRUCTIONS Customer Satisfaction Notification # 771 Radiator Fan Relay
and Reprogram PCM
^ This service requirement applies only to 1998 model year Dodge Caravan and Grand Caravan;
Plymouth Voyager and Grand Voyager; and Chrysler Town & Country (NS) vehicles equipped with
a 2.4L, 3.3L or 3.8L engine ("B", "G", "R" or "L" in the 8th VIN position) built through:
^ November 26, 1997 (MDH 112623) at the St. Louis South Assembly Plant ("B" in the 11th VIN
position)
^ December 1, 1997 (MDH 120109) at the Windsor Assembly Plant ("R" in the 11th VIN position)
^ The radiator fan relay on the above listed vehicles, may not turn on the radiator cooling fans. This
may cause the engine to overheat. To correct this condition, the radiator fan relay must be replaced
and the Powertrain Control Module (PCM) must be reprogrammed (flashed).
^ Effective immediately all repairs on involved vehicles are to be performed according to this
Customer Satisfaction Notification. The Labor Operation Number for TSB 18-33-97 is being
canceled.
Parts Packages:
^ Each involved dealer, to whom vehicles in this notification were invoiced, will receive enough
Radiator Fan Relay Packages to service about 25% of those vehicles.
Owner Letter
CUSTOMER SATISFACTION NOTIFICATION TO REPLACE YOUR VEHICLE'S
RADIATOR FAN RELAY AND REPROGRAM THE POWER TRAIN CONTROL MODULE
Dear Chrysler Minivan Owner:
The satisfaction of our customers is very important to Chrysler. Because of this, we are requesting
owners of some 1998 Dodge Caravan and Grand Caravan; Plymouth Voyager and Grand Voyager;
and Chrysler Town & Country minivans equipped with a 2.4L, 3.3L or 3.8L engine, to return them to
their dealer for a special service.
The problem is...
The radiator fan relay on your minivan (identified on the enclosed form), may not turn on the
radiator cooling fans. This may cause the engine to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Powertrain Management > PROM - Programmable Read Only Memory > Component
Information > Technical Service Bulletins > All Other Service Bulletins for PROM - Programmable Read Only Memory: >
771 > May > 98 > Campaign - Radiator Fan Relay and PCM > Page 4552
overheat.
What Chrysler and your dealer will do...
Chrysler will repair your minivan free of charge (parts and labor). To do this, your dealer will
replace the radiator fan relay and reprogram the powertrain control module. The work will take
about one hour to complete. However, additional time may be necessary depending on how dealer
appointments are scheduled and processed.
What you must do...
^ Simply contact your dealer to schedule a service appointment. Ask the dealer to hold the parts for
your vehicle or to order them before your appointment.
^ Bring the enclosed Owner Notification Form with you to your dealer. It explains the required
service to your dealer.
If you need help...
If you have trouble getting your vehicle repaired, please call the Chrysler Customer Center, toll
free, at 1-800-992-1997. A representative will assist you in getting your vehicle repaired.
We're sorry for any inconvenience, but we believe that this special service will help to ensure your
continuing satisfaction with your vehicle. Thanks for your attention to this important matter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Actuators and Solenoids - Transmission and Drivetrain >
Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4559
Transmission Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Actuators and Solenoids A/T > Shift Solenoid, A/T > Component Information > Locations > Page 4565
Transmission Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions
Clutch: Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions
NUMBER: 26-11-97H
GROUP: Miscellaneous
DATE: November, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number
81-699-97019
DESCRIPTION OF CHANGES
Revisions to Test 53 - Repairing speed ratio in third gear
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4570
294
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4571
298
Revision to the front pump inspection procedures
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4572
380
Revision to the low reverse reaction plate specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Technical Service Bulletins > A/T - 41TE/41TA Service Manual Revisions > Page 4573
413
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch
Clutch: Specifications Low Reverse Clutch
Clutch Retainer ....................................................................................................................................
.................................................... 5 Nm (45 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Specifications > Low Reverse Clutch > Page 4576
Clutch: Specifications 4 Speed Automatic
CLUTCH PACK CLEARANCES:
L/R (Select Reaction Plate)
....................................................................................................................................... 0.89 - 1.04
mm (0.035 - 0.042 inch) 2/4 (No Selection)
..................................................................................................................................................... 0.76
- 2.64 mm (0.030 - 0.104 inch) Reverse (Select Snap Ring)
....................................................................................................................................... 0.76 - 1.24
mm (0.030 - 0.049 inch) Overdrive (No Selection)
.......................................................................................................................................... 0.96 - 2.26
mm (0.038 - 0.089 inch) Underdrive (Select Pressure Plate)
............................................................................................................................ 0.91 - 1.47 mm
(0.036 - 0.058 inch)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch
Clutch: Description and Operation Input Clutch
The input clutch assembly is located directly behind the oil pump housing, and rides on the reaction
shaft support journal. The assembly consists of the following:
- Input shaft
- Input hub
- Clutch retainer
- Clutch pistons Overdrive hub Underdrive hub Three input clutches (underdrive clutch, overdrive
clutch and reverse clutch).
When the torque converter turbine turns, the input shaft, hub and clutch retainer also turn
Each of the three clutches in the input clutch assembly supply input power to a particular
component in the planetary gear train when they are hydraulically applied. They are connected to
the planetary gear-train through the overdrive hub assembly, underdrive hub assembly and the
front sun gear assembly. When any of these clutches are applied, they turn or drive a component
which is an input to the planetary gear-train.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4579
Clutch: Description and Operation Low Reverse Clutch
The Low/Reverse (L/R) clutch is used in both low and reverse gears. The L/R clutch is located in
the back of the case, directly behind the 2-4 clutch. The L/R clutch actually shares the reaction
plate of the 2-4 clutch. It consists of steel plates, clutch discs, belleville return spring, piston and a
stamped steel piston retainer which is secured to the back of the case with screws.
The L/R clutch surrounds the outside of the front carrier assembly, and locks or grounds the front
planetary carrier/rear annulus gear assembly to the case when applied. Similar to the 2-4 clutch,
the L/R clutch is a holding element and eliminates the need for bands.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4580
Clutch: Description and Operation Overdrive and Reverse Clutch
The Overdrive/Reverse (OD/REV) piston is between the input hub and the clutch retainer. This
piston is unique in design for the following reasons:
- It operates two separate clutches
- It is located on the outside of the clutch retainer that houses the two clutches it operates
The overdrive clutch is splined to the overdrive hub assembly, and the overdrive hub is splined to
the front carrier assembly. When the overdrive clutch is applied hydraulically, the front carrier
assembly is an input to the planetary gear-set in third (direct) and fourth (overdrive) gear ranges.
The reverse clutch is splined to the front sun gear assembly. When the reverse clutch is applied
hydraulically, it drives the front sun gear which is the input to the planetary gear-set in reverse gear
range.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4581
Clutch: Description and Operation Underdrive Clutch
The underdrive piston, piston return spring and spring retainer are inside and to the front of the
clutch retainer. These parts control the application of the Underdrive (UD) clutch. The underdrive
clutch is named for its use in the three forward underdrive gear ranges: first, second and third.
The underdrive clutch is splined to the underdrive hub assembly. The underdrive shaft, which is
secured to the underdrive hub, is splined to the rear sun gear. When the underdrive clutch is
applied hydraulically, the rear sun gear is the input to the planetary gear-set in first, second and
third gears.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Input Clutch > Page 4582
Clutch: Description and Operation 2-4 Clutch
The 2-4 clutch is used in both second and fourth gears, and is located directly behind the input
clutch assembly. The clutch consists of the following:
- Stamped steel clutch piston retainer
- Aluminum piston
- Belleville return spring
- Clutch plates
- Steel separator plates
- Reaction Plate
The above parts are held in the case with snap rings. The 2-4 clutch surrounds the outside of the
front sun gear assembly and when applied hydraulically, locks or grounds the front sun gear
assembly to the case.
The 2-4 clutch is a holding element. It is a multidisc clutch that provides more room within the
transaxle, and eliminates the need for using a band and servo as are used in other transaxle
applications.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Description and Operation > Page 4583
Clutch: Testing and Inspection
AIR PRESSURE TESTS
Inoperative clutches can be located using a series of tests by substituting air pressure for fluid
pressure. The clutches may be tested by applying air pressure to their respective passages.
Remove the valve body and then install the special tool MB995053 or equivalent. To make air
pressure tests, go on as follows: The compressed air supply must be free of all dirt and moisture.
Use a pressure of 207 kPa (30 psi). Remove oil pan and valve body. See Valve body removal.
Overdrive Clutch
Apply air pressure to the overdrive clutch apply passage and watch for the push/pull piston to move
forward. The piston should return to its starting position when the air pressure is removed.
Reverse Clutch
Apply air pressure to the reverse clutch apply passage and watch for the push/pull piston to move
rearward. The piston should return to its starting position when the air pressure is removed.
2/4 Clutch
Apply air pressure to the feed hole located on the 2/4 clutch retainer. Look in the area where the
2/4 piston contacts the first separator plate and watch carefully for the 2/4 piston to move rearward.
The piston should return to its original position after the air pressure is removed.
Low/Reverse Clutch
Apply air pressure to the low/reverse clutch feed hole (rear of case, between 2 bolt holes). Then,
look in the area where the low/reverse piston contacts the first separator plate and watch carefully
for the piston to move forward. The piston should return to its original position after the air pressure
is removed.
Underdrive Clutch
Because this clutch piston cannot be seen, its operation is checked by function. Air pressure is
applied to low/reverse and the 2/4 clutches. This locks the output shaft. Use a piece of rubber hose
wrapped around the input shaft and a pair of clamp-on pliers to turn the input shaft. Next apply air
pressure to the underdrive clutch. The input shaft should not rotate with hand torque. Release the
air pressure and confirm that the input shaft will rotate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly
Clutch: Service and Repair Assembly
NOTE: Use petrolatum on all seals to ease assembly of component.
1. Install input shaft to hub.
2. Install input shaft snap ring. Replace lip seals and O-rings. Do not scratch bearing surface.
3. Install return spring and snap ring. Replace O-ring and lip seal of OD/reverse piston.
4. While compressing return spring with Disc 6957, or equivalent and arbor press ram, install snap
ring with a screwdriver.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4586
5. Install overdrive/reverse piston by pushing down. Be sure to lubricate reverse piston O-ring and
lip seal prior to installation.
6. To install input shaft hub assembly to overdrive/reverse piston, rotate input shaft hub to align
splines with overdrive/reverse piston and push down
by hand.
7. Install input hub tapered snap ring with snap ring pliers.
8. Install underdrive clutch piston.
9. Install piston return spring. Install Seal Installer 5067 or equivalent. Coat Installer inner surface
lightly with petroleum jelly. Place Installer into
Input clutch assembly with its large inside diameter facing up.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4587
10. Install underdrive spring retainer.
Remove Installer 5067 or equivalent.
11. While compressing spring with Spring Compressor 5059, or equivalent and arbor press ram,
install snap ring with snap ring pliers.
CAUTION: Compress return spring just enough to install snap ring.
12. Install underdrive clutch pack excluding one clutch disc.
13. Install underdrive clutch reaction plate flat snap ring with a screwdriver.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4588
14. Install last underdrive clutch disc.
15. Install overdrive/underdrive clutch reaction plate with stepped side facing down.
16. Install a new overdrive/underdrive clutches reaction plate tapered snap ring with its tapered
side facing up.
CAUTION: Do not reuse tapered snap ring.
Snap ring ends must be located within one finger of the input clutch hub. Be sure that snap ring is
fully seated, by pushing with screwdriver, into snap ring groove all the way around.
CAUTION: Do not scratch reaction plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4589
17. Set up dial indicator set MB995030 or equivalent and steel bar as shown for checking clutch
clearance. Compress clutch pack with finger to zero
dial indicator.
18. Use hook tool to raise top clutch disc. Read dial indicator. Underdrive clutch pack clearance
must be 0.91 to 1.47 mm (0.0358 to 0.0579 inch).
Select the proper reaction plate to achieve specifications.
19. Install overdrive clutch pack starting with a clutch disc.
20. Install overdrive reaction plate waved snap ring into the wide groove.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4590
21. Install overdrive/reverse pressure plate with stepped side down.
22. While pressure down overdrive/reverse pressure plate with Spring Compressor 5059, or
equivalent and arbor press ram, install flat snap ring.
CAUTION: Press down just enough to expose snap ring groove.
23. Check overdrive clutch pack clearance.
The Overdrive (OD) clutch pack clearance is 1.07 to 2.44 mm (0.421 to 0.0961 inch). If not within
specifications, the clutch is not assembled properly. There is no adjustment for the OD clutch
clearance.
24. Install reverse clutch pack.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4591
25. Install reverse clutch reaction plate with flat side down.
26. Install reverse clutch snap ring with a screwdriver.
27. Raise reverse clutch reaction plate by prying up at two locations with screwdrivers to seat snap
ring.
28. Check reverse clutch pack clearance by lifting reverse clutch reaction plate using a hook tool.
The reverse clutch pack clearance is 0.76 to 1.24 mm (0.0299 to 0.0488 inch). Select the proper
reverse clutch snap ring to achieve specifications.
Thickness:
1.56 mm (0.0614 inch) 1.80 mm (0.0709 inch) 2.05 mm (0.0807 inch) 2.30 mm (0.0906 inch)
All clutch clearances in the input clutch retainer have now been checked and approved. To
complete the assembly of the input clutch retainer, the reverse clutch and the overdrive clutch must
be removed from the retainer.
CAUTION: Do not intermix clutch parts. Keep in the same order.
29. After removing reverse and overdrive clutches, install No. 2 needle bearing with 3 small tabs
facing up.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4592
30. Install underdrive shaft assembly.
31. Install No. 3 thrust washer.
32. Stick No. 3 thrust plate onto overdrive shaft assembly with dabs of petrolatum.
33. Install overdrive shaft assembly. Now that both shaft assemblies and thrust washers are
properly installed, reinstall overdrive clutch and reverse
clutch as shown in steps 19 - 26. Rechecking these clutch clearances is not necessary, as they
were set and approved previously.
34. Reassembly of input clutch assembly is now complete.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4593
Clutch: Service and Repair Disassembly
NOTE: Place input clutches assembly on wood blocks or equivalent, as shown to facilitate
disassembly and reassembly.
1. Tap down reverse clutch reaction plate to remove (or install) snap ring.
2. Using a screwdriver, remove the reverse clutch snap ring.
3. Loosen reverse clutch reaction plate by prying at two locations with screwdrivers as shown.
4. Remove reverse clutch reaction plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4594
5. Remove clutch plates and discs. Tie plates and discs together so they go back in the same
location.
6. Remove overdrive/reverse pressure plate snap ring.
7. Remove overdrive/reverse pressure plate.
8. Remove overdrive/reverse clutch waved snap ring with a screwdriver.
9. Remove overdrive shaft assembly and overdrive clutch pack.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4595
10. Disassemble overdrive clutch pack. Tie plates and discs together so they go back in the same
location.
11. Remove No. 3 and No. 4 thrust plates from overdrive shaft assembly.
12. Remove underdrive shaft assembly.
13. Remove No. 2 needle bearing.
14. Remove overdrive/underdrive clutches reaction plate tapered snap ring. Do not scratch reaction
plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4596
15. Remove overdrive/underdrive clutch reaction plate.
16. Remove one underdrive clutch disc.
17. Remove underdrive clutch reaction plate flat snap ring.
18. Remove clutch plates and discs. Tie together so plates and discs go back into the same
location.
19. Remove snap ring with snap ring pliers while compressing return spring with Spring
Compressor 5059, or equivalent and arbor press ram.
CAUTION: Compress return spring just enough to remove snap ring.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4597
20. Remove underdrive spring retainer and spring.
21. Remove underdrive clutch piston.
22. Remove input hub snap ring with snap ring pliers.
23. Tap on input shaft and hub assembly with a plastic hammer.
24. Remove input shaft and hub assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Clutch, A/T > Component
Information > Service and Repair > Assembly > Page 4598
25. Remove overdrive/reverse piston.
26. Remove snap ring with a screwdriver while compressing return spring with Disc 6057 and arbor
press ram or equivalents.
27. Remove snap ring and return spring.
28. Remove input shaft snap ring.
29. Remove input shaft from hub.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T
- MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T
- MIL ON/Delayed Shifts/Shudder > Page 4607
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T
- MIL ON/Delayed Shifts/Shudder > Page 4608
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb
> 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb
> 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4614
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb
> 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4615
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module > Page 4618
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module > Page 4619
Control Module: Locations Power Distribution Center
Junction Block
Power Distribution Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Locations > Transmission Control Module > Page 4620
Fuse Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4623
Control Module: Diagrams Control Module, A/T
Part 1 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4624
Part 2 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4625
Part 3 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4626
Part 4 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4627
Part 5 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4628
Part 6 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4629
Part 7 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4630
Part 8 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4631
Part 9 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Diagrams > Power Control Module > Page 4632
Part 11 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4635
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 -
Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4636
Control Module: Description and Operation TCM Inputs
General Information
GENERAL INFORMATION
The TCM receives input information and continuously processes this information through its logic
circuits to perform all of the control functions that it is designed to perform. However, some of these
control functions are internal to the TCM, while other control functions are performed when the
TCM provides some type of output signal to another control device or module. The following is a
description of TCM input sensors and output devices.
The TCM uses various inputs to determine when to upshift or downshift and when to engage or
disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous
feedback data for controlling shift quality. Without any input, the TCM has no way to determine the
state of the transaxle and cannot control its operation as designed.
Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other
components through the CCD Bus.
DIRECT (HARD-WIRED) TCM INPUTS
- Battery Feed
- Ignition RUN Signal
- Cranking Signal
- Throttle Position Sensor (TPS) Signal
- Engine speed signal (Distributor or DIS Crankshaft Position Sensor)
- Input Speed Sensor Signal
- Output Speed Sensor Signal
- Transmission Range Sensor**(Includes Transmission Temperature Sensor)
- Transmission Control Relay (Switched Battery)
- L/R Pressure Switch Signal
- 2-4 Pressure Switch Signal
- O/D Pressure Switch Signal
- Park/Neutral Position Switch*
- PRNDL Switch*
- Torque Reduction Request Line (TRD Link)
INDIRECT (CCD BUS) TCM INPUTS
- Target Idle Speed
- Engine Coolant Temperature (ECT) Sensor
- Battery Temperature Sensor*
- Brake Switch
- Engine and Body Identification
- Engine Speed (Verifies Direct Input Engine Speed Signal)
- Speed Control ON/OFF Switch
- Speed Control Set Speed
- A/C Clutch Engagement
- Vehicle Identification Number (VIN)
- Manifold Absolute Pressure (MAP) Sensor
- Torque Reduction Confirmation Response
- Relative Throttle Position (Beginning in 1998)
*: UP TO 1995 **: BEGINNING IN 1996
Battery and Ignition (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4637
BATTERY
A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced
and also fed to the contact side of the Transmission Control Relay. On vehicles with an original
TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the
adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or
road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated
per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in
memory; therefore, a quick learn or road test is not necessary.
IGNITION
When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START
(CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above
approximately 26 volts or below 8 volts, the TCM automatically powers down which results in
limp-in symptoms.
Throttle Position Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4638
The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift
quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5
volt supply and ground for the sensor. Target idle speed is compared against actual engine speed
to determine the learned TPS value for closed throttle idle. This is done to correct for differences in
system voltage and sensor tolerances.
If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by
substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier
vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts
that are vehicle speed dependent.
NOTE: Refer to TSB 18-13-94 if erratic shifting is evident.
Input Speed Sensors and Output Speed Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4639
The input speed sensor provides information to the TCM on how fast the torque converter turbine is
spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing.
The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input
clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is
induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this
information as input shaft rpm. This information is also compared to the output shaft speed and the
engine speed signal to determine the following:
- Planetary gears operating ratio
- Torque converter clutch slippage
- Torque converter element speed ratio
The output speed sensor is located on the same side of the transaxle case as the input speed
sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal
from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the
output speed sensor signal is received by the TCM, the signal is compared to the input speed
signal to determine gear ratio, detect clutch slippage, etc.
Pressure Switches (Hard-Wired)
The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack
Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits.
The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at
approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists
or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic
pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the
shift lever electrical signal is incorrect.
Transmission Temperature Sensor (Hard-Wired) (Beginning 1996)
The Transmission Temperature Sensor is used to monitor the temperature of the transmission
fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based
on the resistance value of the temperature sensor located in the Transmission Range Sensor
(TRS). The primary temperature inputs used by the TCM are the Transmission Temperature
Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be
running to get accurate temperature readings.
NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral
position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position
switch.
If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination
of inputs. The calculated fluid temperature is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4640
continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF.
On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the
vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a
value between the battery temperature and engine coolant temperature signals received from the
PCM over the CCD Bus.
The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The
temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS,
non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a
heat transfer equation that uses engine coolant temperature, battery/ambient temperature and
extended time off (if known) at start up.
Transmission Shift Scheduling
Once the engine is started, the TCM updates the transmission oil temperature based on the
following to determine an estimated oil temperature during vehicle operation (if a calculated oil
temperature is being used):
- Torque converter slip speed
- Vehicle speed
- Engine coolant temperature
- Battery/ambient temperature
Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal
operation. However, if a transmission oil cooler is added, a transmission is overfilled, a
transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the
calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be
inappropriate for the current conditions.
The key highlights of the various shift schedules are as follows:
Extreme Cold: Oil temperature at start up below -16° F.
- Goes to "Cold" schedule above - 12°F oil temperature
- Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent
shifts)
Cold: Oil temperature at start up above - 12 ° F and below 36°F
- Goes to "Warm" schedule above 40° F oil temperature
- Delayed 2-3 upshift (approximately 22 - 31 MPH)
- Delayed 3-4 upshift (45 - 53 MPH)
- Early 4-3 coastdown shift (approximately 30 MPH)
- Early 3-2 coastdown shift (approximately 17 MPH)
- High speed 4-2, 3-2, 2-1 kickdown shifts are prevented
- No EMCC
Warm: Oil temperature at start up above 36° F and below 80° F
- Goes to "Hot" schedule above 80°F oil temperature
- Normal operation (upshift, kick-downs and coast-downs)
- No EMCC
Hot: Oil temperature at start up above 80° F
- Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY)
- Normal operation (upshifts, kick-downs and coast-downs)
- Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH)
Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F
- Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH
97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F
- Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH)
- Delayed 3-4 upshift (41 - 48 MPH)
- 3rd gear FEMCC from 30 - 48 MPH
- 3rd gear PEMCC from 27 - 31 MPH
Super Overheat: 97 MY - Oil temperature above 240°F
- Goes back to "Overheat" below 240 ° F oil temperature
- All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
96 and prior MY - Oil temperature above 260°F
- Goes back to "Overheat" below 260 ° F oil temperature
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4641
- All "Overheat" shift schedule features apply
- 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
Causes for operation in the wrong temperature shift schedule:
Extreme Cold or Cold shift schedule at start up:
- Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only)
- Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only)
- Defective PCM (calculated oil temperature vehicles only)
- Defective sensor circuit (TRS equipped only)
Overheat or Super Overheat shift schedule after extended operation:
- Operation in city traffic or stop-and-go traffic
- Engine idle speed too high - Stuck AIS motor
- Aggressive driving in low gear
- Trailer towing in OD gear position (use "3" position if frequent shifting occurs)
- Cooling system failure causing engine to operate over 230° F
- Engine coolant temperature stays low too long - If engine coolant temperature drops below 150°
F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will
cause the transmission to overheat.
- A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC
disengaged will cause the transmission to overheat.
- Transmission fluid overfilled (TRS equipped only)
- Transmission cooler or cooler lines restricted (TRS equipped only)
- Defective sensor circuit (TRS equipped only)
Engine Speed (Hard-Wired and CCD Broadcast)
The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor,
as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is
required to provide immediate information for use by the TCM control logic. The CCD engine speed
data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid.
MAP Sensor (CCD Broadcast)
The MAP Sensor provides engine load input directly to the PCM, which determines engine torque
load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The
TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades.
Engine Idle Speed (Hard-Wired and CCD Broadcast)
The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle
speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual
engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle.
Brake Switch (CCD Broadcast)
The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque
converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control
when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4642
Battery/Ambient Temperature Sensor (CCD Broadcast)
The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD
broadcast information is used to control charging system, engine and transaxle operation. The
TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM
detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of
the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the
Battery Temperature signal along with engine coolant temperature to calculate the temperature.
Shift Lever Position (SLP)
The TCM identifies the position of the manual lever by comparing the current switch positions of
the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The
primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle
with the presence of an invalid or transition input code. The SLP logic function screens the input
codes from the switches and provides an SLP output signal to control actual gear selection.
Inputs include the codes indicated by the TRS current shift lever position, pressure switch
indications and speed ratio data from the input to most of the other functions in the TCM.
The identified position is stored in memory. The current switch position is determined by sensing
the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM
receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the
Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD
Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on
the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated.
CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with
sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is
a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse
but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed
data will not agree with the expected results for shift lever position = "OD." Therefore, it is important
to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes.
It is extremely important that accurate shift lever position data be available to the TCM. The
accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test,
performed on the DRB Scan Tool, passes without fail.
Torque Management Signal (CCD Broadcast)
With some engines, the TCM sends a direct input, torque management request signal to: the PCM.
This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque
management request signal is used in order to reduce the torque applied in the 2-4 and OD
clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel
injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine
during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a
very short time period. The PCM sends a confirmation of the request to the TCM over the CCD
Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually
be set.
The torque management signal is basically a 9-volt supply to the PCM. A torque management
request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is
called TRD link, which stands for "Torque Reduction Link."
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4643
PRNDL Switch (Hard-Wired)
NOTE: Used up to 1995 (Early 96 NS)
The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along
with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The
TCM uses this input to determine what gear range and shift pattern to use.
Park/Neutral Position Switch (Hard-Wired)
NOTE: Used up to 1995 and early 96 NS
The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and
Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position
Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both
switches must be closed to operate the back-up lamps.
Transmission Range Sensor (Hard-Wired)
The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission
Range Switch that are found on vehicles prior to the 1996
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4644
MY. This sensor allows for accurate transaxle gear position identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4645
Control Module: Description and Operation TCM Outputs
General Information
The TCM directly controls the following:
- Transmission Control Relay
- Solenoid pack
- Torque management requests to the PCM
Additionally, the TCM broadcasts the following information over the CCD Bus for use by other
vehicle control systems (Indirect Outputs):
- Communication with the DRB Scan Tool for diagnostics
- Shift lever position to the BCM
- Shift lever position to the shift lever display
- Transmission oil temperature to the PCM in order to activate the cooling fans
- Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus
- Limp - in Status
- Transmission Temperature
- In-gear position
NOTE: MIL request is from the PCM.
Transmission Control Relay
The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal
electronic circuits are all working properly. If the self-test results are good, then the TCM sends
battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts,
which then supply battery voltage to the TCM, the four solenoids and the three pressure switches
in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to
the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then
stored in memory. The Transmission Control Relay is located in various places depending on the
vehicle model.
Solenoid and Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4646
When the Transmission Control Relay contact points are closed, the solenoid assembly receives
electrical power. The TCM can then operate the solenoids, as determined by its programming. The
relay provides power to all four solenoids through a single wire. This means that all the solenoids
have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids,
however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is
needed.
The assembly is mounted to the outside of the transaxle case, under a sound shield protective
cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel
plate. There are also small solenoid valve filters used to protect the valves from contamination.
These filters are not replaceable. If the valve body and solenoid pack have been heavily
contaminated, the solenoid pack should be closely inspected to determine if it should be replaced.
The solenoid pack is not a serviceable unit.
The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control
Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to
four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the
solenoid/valves is that they directly control the application of a clutch. In other electronically
controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through
normal hydraulic valving. The solenoid assembly also contains pressure switches that feed
information to the TCM.
Vehicle Speed Signal
The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor
signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output
speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM.
The PCM receives this signal and converts it to a signal that can be used by the Body Control
Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent
over the CCD Bus.
Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4647
On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive
lockout function operated by a button on the instrument panel. The lockout feature makes driving
smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the
transaxle may shift in and out of overdrive, causing unnecessary shifting.
NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ
vehicles use a momentary contact switch.
Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and
provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to
normal operation and turn off the overdrive lockout lamp.
With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If
the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3
upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an
earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the
overdrive lockout switch or selection of the "3" position.
Electronic Pinion Factor
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRB Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration:
- If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when moving
- Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification
Use the following procedures to set the electronic pinion factor using the DRB Scan Tool:
- Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will
display the current tire size.
- If the tire size is incorrect, depress the Enter key and then select the correct size.
- Depress the Page Back key to exit the reset procedure.
Shifter/Ignition Interlock
The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the
automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The
interlock system locks the floor mounted shift lever into the PARK position whenever the ignition
switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the
shifter is unlocked and will move into any position. The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK
position.
Shift Position Indicator
The shifter position indicator is located in the instrument cluster. The shifter position indicator
outlines with a box the gear position the transaxle manual valve lever is in.
The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM
on the position of the transaxle manual valve lever. The TCM receives the switch signal and
processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the
CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster.
Autostick
Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When
the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using
before Autostick was activated. Moving the shifter to the left (towards the driver) causes a
downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument
cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while
in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift
schedule.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Description and Operation > General Information > Page 4648
Automatic Overrides
Some shifts are executed automatically or prevented Automatic shifts will occur under the
illustrated conditions:
Additionally, under certain circumstances, the TCM may take over and override the autostick
features, for example, under the following conditions:
- Autostick switch input errors
- Error overspeed
- Engine overheating
- Transmission overheating Autostick shifts are not permitted under the illustrated conditions:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Control Module, A/T >
Component Information > Service and Repair > General Information > Page 4651
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations
Data Link Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Data Link Connector, A/T
> Component Information > Locations > Page 4655
Data Link Connector (16 - Way)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Differential Carrier Assembly, A/T > Carrier Bearings, A/T > Component Information > Specifications
Carrier Bearings: Specifications
Retainer Bolts ......................................................................................................................................
..................................................... 28 Nm (21 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Differential Case, A/T > Component Information > Specifications
Differential Case: Specifications
Mounting Bolts .....................................................................................................................................
............................................... 19 Nm (165 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Differential, Automatic
Transaxle > Ring Gear, A/T > Component Information > Specifications
Ring Gear: Specifications
Mounting Bolts .....................................................................................................................................
.................................................... 95 Nm (70 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Extension Housing, A/T >
Component Information > Specifications
Extension Housing: Specifications
Mounting Bolts .....................................................................................................................................
.................................................... 28 Nm (21 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage
Fluid - A/T: Technical Service Bulletins A/T - ATF + 4 Fluid Usage
NUMBER: 21-014-07
GROUP: Transmission
DATE: October 16, 2007
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-010-06, DATED APRIL 14,
2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES THE ADDITION OF THE ASIAN
WARNER (AW4) TRANSMISSION AND ADDITIONAL MODELS AND YEARS.
SUBJECT: Automatic Transmission Fluid Usage ATF+4 (Type M59602)
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1989 - 2003 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1993 (AD) Ram Truck
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1995 (AJ) Lebaron Coupe/Lebaron Convertible
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker fifth Avenue
1989 - 2004 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1990 - 1991 (AQ) Maserati
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2003 (BR/BE) Ram Truck
2004 - **2008** (CS) Pacifica
1998-2003 (DN) Durango
2002 - **2008** (DR/DH/D1) Ram Truck
2007 - **2008** (DC) Ram 3500 Cab Chassis
1995 - 2000 (FJ) Sebring/Avenger/Talon
1996 - 2000 (GS) Chrysler Voyager (International Market)
2004 - **2008** (HB) Durango
**2008 (HG) Aspen**
1995 - 2000 (JA) Cirrus/Stratus/Breeze
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4674
2007 - **2008** (JK) Wrangler
2001 - 2006 (JR) Sebring Sedan & Convertible/Stratus Sedan
2007 - **2008** (JS) Avenger/Sebring/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
**2007 - 2008 (KA) Nitro**
2002 - 2007 (KJ) Liberty
**2008 (KK) Liberty**
**2008 (L2) 300C (China)**
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker /300M
2005 - **2008** (LX/LE) 300/Magnum/Charger
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2005 (PL) Neon
2002 - 2003 (PG) PT Cruiser (International Markets)
2001 - **2008** (PT) PT Cruiser
1997 - 2002 (PR) Prowler
2001 - 2007 (RG) Chrysler Voyager (International Markets)
2001 - 2007 (RS) Town & Country/Caravan/Voyager
**2008 (RT) Town & Country/Grand Caravan/Grand Voyager (U.S. & International Markets)**
1997-2006 (TJ) Wrangler
2001 - 2004 (WG) Grand Cherokee (International Markets) Vehicles equipped with Gas engines
1999 - 2004 (WJ) Grand Cherokee
2005 - **2008** (WK/WH) Grand Cherokee
2006 - **2008** (XK/XH) Commander
1989 - 1995 (YJ) Wrangler
**1989 - 2001 (XJ) Cherokee**
**1989 - 1993 (MJ) Comanche**
1996 - 1998 (ZG) Grand Cherokee (International Markets)
1994 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
**AWA (Asian Warner) transmission are now included in this Service Bulletin. ATF+4(R) is
recommended for AW-4 (Asian Warner) transmissions**
NOTE:
This Service Bulletin DOES NOT apply to Sprinter transmissions, Crossfire transmissions, MK/PM
vehicles equipped with Continuously Variable
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Technical Service Bulletins > A/T - ATF + 4 Fluid Usage > Page 4675
Transmission (CVT) and WG vehicles equipped with a diesel engine (sales code ENF) and a
W5J400 or NAG1 transmission (sales code DGJ).
DISCUSSION:
ATF+4(R) - (Type 9602) is being used as factory fill for Chrysler Group automatic transmissions.
ATF+4(R) is recommended for all vehicles equipped with Chrysler Group automatic transmissions
EXCEPT FOR THOSE LISTED IN THE NOTE ABOVE.
NOTE:
ATF+4(R) must always be used in vehicles that were originally filled with ATF+4(R). DO NOT USE
ANY OTHER FLUID.
NOTE:
ATF+4(R) is backward compatible with ATF+3, ATF+2, and ATF+. Additionally, ATF+4(R) can be
used to top off vehicles that used ATF+3, ATF+2, or ATF+.
NOTE:
If ATF+4® is used to service models originally filled with ATF+3, ATF+2, and ATF+ the fluid
maintenance schedules listed for that model does not change. The service interval currently in
effect for a given model should continue to be followed. Refer to the Service or Owners manual for
maintenance schedule directions.
In general terms, If ATF+, ATF+2 or ATF+3 was the recommended fluid, it is now recommended to
use ATF+4®
BENEFITS
^ Better anti-wear properties
^ Improved rust/corrosion prevention
^ Controls oxidation
^ Eliminates deposits
^ Controls friction
^ Retains anti-foaming properties
^ Superior properties for low temperature operation
FLUID COLOR
Mopar ATF+4(R) has exceptional durability. However, the red dye used in ATF+4(R) is not
permanent; as the fluid ages it may become darker or appear brown in color. ATF+4(R) also has a
unique odor that may change with age. With ATF+4(R) fluid, color and odor are no longer
indicators of fluid condition and do not necessarily support a fluid change.
PARTS REQUIRED:
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications
Fluid - A/T: Capacity Specifications
Transmission Fluid
31TH ....................................................................................................................................................
............................................................. 8.0L (8.5 Qt) 41TE .................................................................
................................................................................................................................................ 8.6L
(9.1 Qt)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Specifications > Capacity Specifications > Page 4678
Fluid - A/T: Fluid Type Specifications
See TSB 21-010-06 4/14/2006
Transmission Fluid Type
Type
.........................................................................................................................................................
Mopar (R) ATF Plus 4 Type 9602, Or Equivalent
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check
Fluid - A/T: Service and Repair Fluid Level & Condition Check
Fluid Level
The transmission and differential sump have a common oil sump with a opening between the two.
The torque converter fills in both the "P" Park and "N" Neutral positions.
Place the selector lever in "P" Park to check fluid level.
The engine should be running at idle speed for at least one minute, with the vehicle on level
ground. This will assure complete oil level stabilization between differential and transmission.
The fluid should be at normal operating temperature (approximately 82 C. or 180 F).
The fluid level is correct if it is in the "HOT" region (cross-hatched area) on the oil level indicator.
Fluid Condition
Along with fluid level, it is important to check the condition of the fluid.
- When the fluid smells burned, and is contaminated with metal or friction material particles, a
complete transaxle overhaul is needed.
Be sure to examine the fluid on the dipstick closely.
- If there is any doubt about its condition, drain out a sample for a double check.
Note: After the fluid has been checked, seat the dipstick fully to seal out water and dirt.
Low Fluid Level Symptoms
Low fluid level can cause a variety of conditions because it allows the pump to take in air along with
the fluid. in any hydraulic system, air bubbles will make the fluid spongy, therefore pressures will be
low and build up slowly.
Improper Filling Level Symptoms
Improper filling can also raise the fluid level too high.
- When the transaxle has too much fluid, the gears churn up foam and cause the same conditions
which occur with a low fluid level.
In either case the air bubbles can cause over heating, fluid oxidation, and varnishing, which can
interfere with normal valve, clutch and accumulator operation.
Foaming can also result in fluid escaping from the transaxle vent, where it may be mistaken for a
leak.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check > Page 4681
Fluid - A/T: Service and Repair Fluid and Filter Change
Fluid and Filter Change
When the factory fill fluid is changed, only fluids labeled Mopar ATF+4 (Automatic Transmission
Fluid) Type 9602 should be used. A filter change should be made at the time of oil change. Also
the magnet (on the inside of the oil pan) should be cleaned with a clean dry cloth. If the transaxle is
disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid - A/T > Component
Information > Service and Repair > Fluid Level & Condition Check > Page 4682
Fluid - A/T: Service and Repair Fluid Drain and Refill
Procedure
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan.
2. Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan.
3. Install a new filter and O-ring on bottom of the valve body.
4. Clean the oil pan and magnet. Reinstall pan using Mopar RTV Sealant. Tighten oil pan bolts to
19 Nm (165 in-lbs).
5. Pour four quarts of Mopar ATF+4 (Automatic Transmission Fluid) Type 9602 through the fill
tube.
6. Start engine and allow to idle for at least one minute. Then, with parking and service brakes
applied, move selector lever momentarily to each position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark on the dipstick.
CAUTION: Do not over fill transaxle. Do not add oil if level is between: Lower holes for warm oil
(100F). Upper holes for hot oil (180F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region.
9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the dipstick fill
tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Fluid Drain and Refill
Fluid Filter - A/T: Service and Repair Fluid Drain and Refill
1. Raise vehicle on a hoist. Place a drain container with a large opening, under transaxle oil pan. 2.
Loosen pan bolts and tap the pan at one corner to break it loose allowing fluid to drain, then
remove the oil pan. 3. Install a new filter and O-ring on bottom of the valve body. 4. Clean the oil
pan and magnet. Reinstall pan using new MOPAR RTV sealant. Tighten oil pan bolts to 19 Nm
(165 inch lbs.). 5. Pour four quarts of MOPAR ATF+4 (Automatic Transmission Fluid) Type 9602
through the fill tube. 6. Start engine and allow to idle for at least one minute. Then, with parking and
service brakes applied, move selector lever momentarily to each
position, ending in the park or neutral position.
7. Add sufficient fluid to bring level to 1/8 inch below the ADD mark.
CAUTION: Do not overfill transaxle. Do not acid oil if level is between: Lower holes for warm oil
(100°F). Upper holes for hot oil (180°F).
8. Recheck fluid level after transaxle is at normal operating temperature. The level should be in the
HOT region. 9. To prevent dirt from entering transaxle, make certain that dipstick is seated into the
dipstick fill tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Filter - A/T >
Component Information > Service and Repair > Fluid Drain and Refill > Page 4687
Fluid Filter - A/T: Service and Repair Fluid & Filter Change
When the factory fill fluid is changed, only fluids labeled MOPAR ATF Plus 4 (Automatic
Transmission fluid) Type 7176, or equivalent should be used. A filter change should be made at the
time of the oil change. Also the magnet (on the inside of the oil pan) should be cleaned with a
clean, dry cloth.
If the transaxle is disassembled for any reason, the fluid and filter should be changed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > A/T Oil Cooler Line Hose Clamp - Revised
Fluid Line/Hose: Technical Service Bulletins A/T Oil Cooler Line Hose Clamp - Revised
NUMBER: 07-006-01
GROUP: Cooling
DATE: Nov. 11, 2001
SUBJECT: Transmission Oil Cooler Line Hose Clamp Service
OVERVIEW: This bulletin provides revised transmission oil cooler hose clamp information.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
DISCUSSION:
A revised transmission oil cooler hose clamp is now available and should be used any time it is
necessary to separate oil cooler hose connections. Tighten the clamp(s) to 3.2 Nm (28 in. lbs.).
Transmission oil cooler hoses should be replaced only it they are damaged.
NOTE:
WEATHERED SURFACE APPEARANCE ON TRANSMISSION OIL COOLER HOSES IS A
NORMAL CONDITION AND WILL NOT IMPAIR THEIR ABILITY TO SEAL.
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Page 4692
Fluid Line/Hose: Specifications
Fittings .................................................................................................................................................
............................................... 12 Nm (105 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Line/Hose, A/T >
Component Information > Technical Service Bulletins > Page 4693
Fluid Line/Hose: Service and Repair
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also. The torque converter must also be replaced
with an exchange unit. This will insure that metal particles or sludged oil are not later transferred
back into the reconditioned (or replaced) transaxle.
The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher.
WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear
standard industrial rubber gloves.
- Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent
the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where
the flusher will be used.
- Keep the area well ventilated.
- Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs,
flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin
with soap and water. Seek medical attention.
COOLER FLUSH USING TOOL 6906A
1. Remove cover plate filler plug on Tool 6906A, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh
flushing solution. Flushing solvents are
petroleum based solutions generally used to clean automatic transmission components. DO NOT
use solvents containing acids, water, gasoline, or any other corrosive liquids.
2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red
alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4.
Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush.
5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR
return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s)
and lines. Monitor pressure
readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles
equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is
intermittent or exceeds these pressures, replace cooler.
8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect
CLEAR return line at cover plate, and place it in a drain pan.
10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump
OFF. 11. Place CLEAR suction line into a one quart container of Mopar (R) ATF Plus 4 Type 7176
automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one
quart container and lines. This purges any residual cleaning solvent from the
transmission cooler and lines. Turn pump OFF.
13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove
flushing adapters from cooler lines. 14. Check for debris on cooler and remove.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pan, A/T >
Component Information > Specifications
Fluid Pan: Specifications
TORQUE SPECIFICATIONS
Bolt, Oil Pan-to-Case ...........................................................................................................................
..................................................... 19 Nm (14 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4705
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4706
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4707
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4713
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4714
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4715
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov >
97 > A/T - 41TE/41TA Service Manual Revisions
Fluid Pump: All Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions
NUMBER: 26-11-97H
GROUP: Miscellaneous
DATE: November, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number
81-699-97019
DESCRIPTION OF CHANGES
Revisions to Test 53 - Repairing speed ratio in third gear
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov >
97 > A/T - 41TE/41TA Service Manual Revisions > Page 4720
294
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov >
97 > A/T - 41TE/41TA Service Manual Revisions > Page 4721
298
Revision to the front pump inspection procedures
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov >
97 > A/T - 41TE/41TA Service Manual Revisions > Page 4722
380
Revision to the low reverse reaction plate specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Fluid Pump: > 26-11-97H > Nov >
97 > A/T - 41TE/41TA Service Manual Revisions > Page 4723
413
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97
> A/T - 41TE/41TA Service Manual Revisions
Fluid Pump: All Technical Service Bulletins A/T - 41TE/41TA Service Manual Revisions
NUMBER: 26-11-97H
GROUP: Miscellaneous
DATE: November, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 41TE/41TA Service/Diagnostic Procedures Manual - Publication Number
81-699-97019
DESCRIPTION OF CHANGES
Revisions to Test 53 - Repairing speed ratio in third gear
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97
> A/T - 41TE/41TA Service Manual Revisions > Page 4729
294
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97
> A/T - 41TE/41TA Service Manual Revisions > Page 4730
298
Revision to the front pump inspection procedures
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97
> A/T - 41TE/41TA Service Manual Revisions > Page 4731
380
Revision to the low reverse reaction plate specifications
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Fluid Pump: > 26-11-97H > Nov > 97
> A/T - 41TE/41TA Service Manual Revisions > Page 4732
413
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Page 4733
Fluid Pump: Specifications
CLEARANCES:
Outer Gear To Pocket
....................................................................................................................................... 0.045 - 0.141
mm (0.0018 - 0.0056 inch) Outer Gear Side Clearance
................................................................................................................................ 0.020 - 0.046 mm
(0.0008 - 0.0018 inch) Inner Gear Side Clearance
................................................................................................................................ 0.020 - 0.046 mm
(0.0008 - 0.0018 inch)
TIGHTENING TORQUE:
Mounting Bolts .....................................................................................................................................
................................................ 27 Nm (20 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Page 4734
Fluid Pump: Description and Operation
The oil pump is located in the pump housing inside of the bell housing of the transaxle case, and is
similar to oil pumps used in other Chrysler applications. The inner gear is driven by the torque
converter impeller hub. Torque is supplied to the impeller hub by the engine crankshaft through the
flex plate and converter housing.
As the gears rotate, the clearance between the gear teeth increases in the crescent area, and
creates a suction at the inlet side of the pump. Fluid is pulled through the pump inlet from the oil
pan. As the clearance between the gear teeth in the crescent area decreases, it forces fluid into the
pump outlet. The pressurized oil from the outlet operates the torque converter, clutches and the
lubrication system. The pump is held in the housing by the reaction shaft support
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Fluid Pump, A/T >
Component Information > Technical Service Bulletins > Page 4735
Fluid Pump: Testing and Inspection
After the new or repaired transmission has been installed, fill to the proper level with Mopar (R)
ATF Plus 4 (Type 7176), or equivalent automatic transmission fluid. The volume should be checked
using the following procedure:
1. Disconnect the From cooler line at the transmission and place a collecting container under the
disconnected line.
CAUTION: With the fluid set at the proper level, fluid collection should not exceed (1) quart or
internal damage to the transmission may occur.
2. Run the engine at curb idle speed, with the shift selector in neutral. 3. If fluid flow is intermittent
or it takes more than 20 seconds to collect one quart of ATF, disconnect the To Cooler line at the
transaxle. 4. Refill the transaxle to proper level and recheck pump volume. 5. If flow is found to be
within acceptable limits, replace the cooler. Then fill.transmission to the paper level, using. Mopar
(R) ATF Plus 4 (Type
7176), or equivalent automatic transmission fluid.
6. If fluid flow is still found-to be inadequate, check the line pressure using the Transaxle Hydraulic
Pressure Test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information
Planetary Gears: Description and Operation General Information
The entire planetary gear-train is located behind the input clutch assembly and is inside the 2-4 and
L/R clutch assemblies. The planetary gear-train consists of two sun gears, two planetary carriers,
two annulus (ring) gears and one output shaft which is part of the rear carrier.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information > Page 4740
Planetary Gears: Description and Operation Front Carrier Assembly
The front planetary carrier and gear annulus (ring) gear are splined together as one unit. When the
overdrive clutch is applied, it drives the front carrier assembly by the overdrive hub. When the
low/reverse clutch is applied, it holds or prevents the front carrier assembly from rotating.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Planetary Gears, A/T >
Component Information > Description and Operation > General Information > Page 4741
Planetary Gears: Description and Operation Rear Carrier Assembly
The rear planetary carrier, front annulus (ring) gear and output shaft are all one assembly. The rear
carrier assembly provides all output power for the transaxle assembly. In other words, all output
from the transaxle must go through the rear carrier. The lugs around the outside of the assembly
have two purposes:
- To engage the parking pawl when the driver selects park
- To generate an output speed signal used by the TCM
There are no clutches splined or connected to this unit in any way. The rear carrier assembly is
supported to the case by two tapered roller bearings, which must be set up with specific preload
and measured by turning torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4751
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for Control Module: >
21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4752
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4758
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Control
Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 4759
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4762
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4763
Control Module: Locations Power Distribution Center
Junction Block
Power Distribution Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Locations > Transmission Control Module > Page 4764
Fuse Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4767
Control Module: Diagrams Control Module, A/T
Part 1 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4768
Part 2 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4769
Part 3 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4770
Part 4 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4771
Part 5 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4772
Part 6 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4773
Part 7 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4774
Part 8 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4775
Part 9 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 4776
Part 11 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4779
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 -
Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4780
Control Module: Description and Operation TCM Inputs
General Information
GENERAL INFORMATION
The TCM receives input information and continuously processes this information through its logic
circuits to perform all of the control functions that it is designed to perform. However, some of these
control functions are internal to the TCM, while other control functions are performed when the
TCM provides some type of output signal to another control device or module. The following is a
description of TCM input sensors and output devices.
The TCM uses various inputs to determine when to upshift or downshift and when to engage or
disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous
feedback data for controlling shift quality. Without any input, the TCM has no way to determine the
state of the transaxle and cannot control its operation as designed.
Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other
components through the CCD Bus.
DIRECT (HARD-WIRED) TCM INPUTS
- Battery Feed
- Ignition RUN Signal
- Cranking Signal
- Throttle Position Sensor (TPS) Signal
- Engine speed signal (Distributor or DIS Crankshaft Position Sensor)
- Input Speed Sensor Signal
- Output Speed Sensor Signal
- Transmission Range Sensor**(Includes Transmission Temperature Sensor)
- Transmission Control Relay (Switched Battery)
- L/R Pressure Switch Signal
- 2-4 Pressure Switch Signal
- O/D Pressure Switch Signal
- Park/Neutral Position Switch*
- PRNDL Switch*
- Torque Reduction Request Line (TRD Link)
INDIRECT (CCD BUS) TCM INPUTS
- Target Idle Speed
- Engine Coolant Temperature (ECT) Sensor
- Battery Temperature Sensor*
- Brake Switch
- Engine and Body Identification
- Engine Speed (Verifies Direct Input Engine Speed Signal)
- Speed Control ON/OFF Switch
- Speed Control Set Speed
- A/C Clutch Engagement
- Vehicle Identification Number (VIN)
- Manifold Absolute Pressure (MAP) Sensor
- Torque Reduction Confirmation Response
- Relative Throttle Position (Beginning in 1998)
*: UP TO 1995 **: BEGINNING IN 1996
Battery and Ignition (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4781
BATTERY
A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced
and also fed to the contact side of the Transmission Control Relay. On vehicles with an original
TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the
adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or
road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated
per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in
memory; therefore, a quick learn or road test is not necessary.
IGNITION
When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START
(CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above
approximately 26 volts or below 8 volts, the TCM automatically powers down which results in
limp-in symptoms.
Throttle Position Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4782
The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift
quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5
volt supply and ground for the sensor. Target idle speed is compared against actual engine speed
to determine the learned TPS value for closed throttle idle. This is done to correct for differences in
system voltage and sensor tolerances.
If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by
substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier
vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts
that are vehicle speed dependent.
NOTE: Refer to TSB 18-13-94 if erratic shifting is evident.
Input Speed Sensors and Output Speed Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4783
The input speed sensor provides information to the TCM on how fast the torque converter turbine is
spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing.
The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input
clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is
induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this
information as input shaft rpm. This information is also compared to the output shaft speed and the
engine speed signal to determine the following:
- Planetary gears operating ratio
- Torque converter clutch slippage
- Torque converter element speed ratio
The output speed sensor is located on the same side of the transaxle case as the input speed
sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal
from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the
output speed sensor signal is received by the TCM, the signal is compared to the input speed
signal to determine gear ratio, detect clutch slippage, etc.
Pressure Switches (Hard-Wired)
The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack
Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits.
The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at
approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists
or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic
pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the
shift lever electrical signal is incorrect.
Transmission Temperature Sensor (Hard-Wired) (Beginning 1996)
The Transmission Temperature Sensor is used to monitor the temperature of the transmission
fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based
on the resistance value of the temperature sensor located in the Transmission Range Sensor
(TRS). The primary temperature inputs used by the TCM are the Transmission Temperature
Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be
running to get accurate temperature readings.
NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral
position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position
switch.
If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination
of inputs. The calculated fluid temperature is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4784
continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF.
On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the
vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a
value between the battery temperature and engine coolant temperature signals received from the
PCM over the CCD Bus.
The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The
temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS,
non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a
heat transfer equation that uses engine coolant temperature, battery/ambient temperature and
extended time off (if known) at start up.
Transmission Shift Scheduling
Once the engine is started, the TCM updates the transmission oil temperature based on the
following to determine an estimated oil temperature during vehicle operation (if a calculated oil
temperature is being used):
- Torque converter slip speed
- Vehicle speed
- Engine coolant temperature
- Battery/ambient temperature
Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal
operation. However, if a transmission oil cooler is added, a transmission is overfilled, a
transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the
calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be
inappropriate for the current conditions.
The key highlights of the various shift schedules are as follows:
Extreme Cold: Oil temperature at start up below -16° F.
- Goes to "Cold" schedule above - 12°F oil temperature
- Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent
shifts)
Cold: Oil temperature at start up above - 12 ° F and below 36°F
- Goes to "Warm" schedule above 40° F oil temperature
- Delayed 2-3 upshift (approximately 22 - 31 MPH)
- Delayed 3-4 upshift (45 - 53 MPH)
- Early 4-3 coastdown shift (approximately 30 MPH)
- Early 3-2 coastdown shift (approximately 17 MPH)
- High speed 4-2, 3-2, 2-1 kickdown shifts are prevented
- No EMCC
Warm: Oil temperature at start up above 36° F and below 80° F
- Goes to "Hot" schedule above 80°F oil temperature
- Normal operation (upshift, kick-downs and coast-downs)
- No EMCC
Hot: Oil temperature at start up above 80° F
- Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY)
- Normal operation (upshifts, kick-downs and coast-downs)
- Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH)
Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F
- Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH
97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F
- Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH)
- Delayed 3-4 upshift (41 - 48 MPH)
- 3rd gear FEMCC from 30 - 48 MPH
- 3rd gear PEMCC from 27 - 31 MPH
Super Overheat: 97 MY - Oil temperature above 240°F
- Goes back to "Overheat" below 240 ° F oil temperature
- All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
96 and prior MY - Oil temperature above 260°F
- Goes back to "Overheat" below 260 ° F oil temperature
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4785
- All "Overheat" shift schedule features apply
- 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
Causes for operation in the wrong temperature shift schedule:
Extreme Cold or Cold shift schedule at start up:
- Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only)
- Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only)
- Defective PCM (calculated oil temperature vehicles only)
- Defective sensor circuit (TRS equipped only)
Overheat or Super Overheat shift schedule after extended operation:
- Operation in city traffic or stop-and-go traffic
- Engine idle speed too high - Stuck AIS motor
- Aggressive driving in low gear
- Trailer towing in OD gear position (use "3" position if frequent shifting occurs)
- Cooling system failure causing engine to operate over 230° F
- Engine coolant temperature stays low too long - If engine coolant temperature drops below 150°
F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will
cause the transmission to overheat.
- A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC
disengaged will cause the transmission to overheat.
- Transmission fluid overfilled (TRS equipped only)
- Transmission cooler or cooler lines restricted (TRS equipped only)
- Defective sensor circuit (TRS equipped only)
Engine Speed (Hard-Wired and CCD Broadcast)
The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor,
as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is
required to provide immediate information for use by the TCM control logic. The CCD engine speed
data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid.
MAP Sensor (CCD Broadcast)
The MAP Sensor provides engine load input directly to the PCM, which determines engine torque
load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The
TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades.
Engine Idle Speed (Hard-Wired and CCD Broadcast)
The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle
speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual
engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle.
Brake Switch (CCD Broadcast)
The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque
converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control
when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4786
Battery/Ambient Temperature Sensor (CCD Broadcast)
The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD
broadcast information is used to control charging system, engine and transaxle operation. The
TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM
detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of
the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the
Battery Temperature signal along with engine coolant temperature to calculate the temperature.
Shift Lever Position (SLP)
The TCM identifies the position of the manual lever by comparing the current switch positions of
the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The
primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle
with the presence of an invalid or transition input code. The SLP logic function screens the input
codes from the switches and provides an SLP output signal to control actual gear selection.
Inputs include the codes indicated by the TRS current shift lever position, pressure switch
indications and speed ratio data from the input to most of the other functions in the TCM.
The identified position is stored in memory. The current switch position is determined by sensing
the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM
receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the
Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD
Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on
the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated.
CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with
sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is
a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse
but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed
data will not agree with the expected results for shift lever position = "OD." Therefore, it is important
to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes.
It is extremely important that accurate shift lever position data be available to the TCM. The
accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test,
performed on the DRB Scan Tool, passes without fail.
Torque Management Signal (CCD Broadcast)
With some engines, the TCM sends a direct input, torque management request signal to: the PCM.
This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque
management request signal is used in order to reduce the torque applied in the 2-4 and OD
clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel
injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine
during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a
very short time period. The PCM sends a confirmation of the request to the TCM over the CCD
Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually
be set.
The torque management signal is basically a 9-volt supply to the PCM. A torque management
request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is
called TRD link, which stands for "Torque Reduction Link."
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4787
PRNDL Switch (Hard-Wired)
NOTE: Used up to 1995 (Early 96 NS)
The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along
with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The
TCM uses this input to determine what gear range and shift pattern to use.
Park/Neutral Position Switch (Hard-Wired)
NOTE: Used up to 1995 and early 96 NS
The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and
Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position
Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both
switches must be closed to operate the back-up lamps.
Transmission Range Sensor (Hard-Wired)
The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission
Range Switch that are found on vehicles prior to the 1996
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4788
MY. This sensor allows for accurate transaxle gear position identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4789
Control Module: Description and Operation TCM Outputs
General Information
The TCM directly controls the following:
- Transmission Control Relay
- Solenoid pack
- Torque management requests to the PCM
Additionally, the TCM broadcasts the following information over the CCD Bus for use by other
vehicle control systems (Indirect Outputs):
- Communication with the DRB Scan Tool for diagnostics
- Shift lever position to the BCM
- Shift lever position to the shift lever display
- Transmission oil temperature to the PCM in order to activate the cooling fans
- Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus
- Limp - in Status
- Transmission Temperature
- In-gear position
NOTE: MIL request is from the PCM.
Transmission Control Relay
The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal
electronic circuits are all working properly. If the self-test results are good, then the TCM sends
battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts,
which then supply battery voltage to the TCM, the four solenoids and the three pressure switches
in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to
the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then
stored in memory. The Transmission Control Relay is located in various places depending on the
vehicle model.
Solenoid and Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4790
When the Transmission Control Relay contact points are closed, the solenoid assembly receives
electrical power. The TCM can then operate the solenoids, as determined by its programming. The
relay provides power to all four solenoids through a single wire. This means that all the solenoids
have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids,
however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is
needed.
The assembly is mounted to the outside of the transaxle case, under a sound shield protective
cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel
plate. There are also small solenoid valve filters used to protect the valves from contamination.
These filters are not replaceable. If the valve body and solenoid pack have been heavily
contaminated, the solenoid pack should be closely inspected to determine if it should be replaced.
The solenoid pack is not a serviceable unit.
The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control
Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to
four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the
solenoid/valves is that they directly control the application of a clutch. In other electronically
controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through
normal hydraulic valving. The solenoid assembly also contains pressure switches that feed
information to the TCM.
Vehicle Speed Signal
The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor
signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output
speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM.
The PCM receives this signal and converts it to a signal that can be used by the Body Control
Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent
over the CCD Bus.
Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4791
On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive
lockout function operated by a button on the instrument panel. The lockout feature makes driving
smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the
transaxle may shift in and out of overdrive, causing unnecessary shifting.
NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ
vehicles use a momentary contact switch.
Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and
provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to
normal operation and turn off the overdrive lockout lamp.
With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If
the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3
upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an
earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the
overdrive lockout switch or selection of the "3" position.
Electronic Pinion Factor
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRB Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration:
- If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when moving
- Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification
Use the following procedures to set the electronic pinion factor using the DRB Scan Tool:
- Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will
display the current tire size.
- If the tire size is incorrect, depress the Enter key and then select the correct size.
- Depress the Page Back key to exit the reset procedure.
Shifter/Ignition Interlock
The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the
automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The
interlock system locks the floor mounted shift lever into the PARK position whenever the ignition
switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the
shifter is unlocked and will move into any position. The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK
position.
Shift Position Indicator
The shifter position indicator is located in the instrument cluster. The shifter position indicator
outlines with a box the gear position the transaxle manual valve lever is in.
The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM
on the position of the transaxle manual valve lever. The TCM receives the switch signal and
processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the
CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster.
Autostick
Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When
the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using
before Autostick was activated. Moving the shifter to the left (towards the driver) causes a
downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument
cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while
in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift
schedule.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Description and Operation > General Information > Page 4792
Automatic Overrides
Some shifts are executed automatically or prevented Automatic shifts will occur under the
illustrated conditions:
Additionally, under certain circumstances, the TCM may take over and override the autostick
features, for example, under the following conditions:
- Autostick switch input errors
- Error overspeed
- Engine overheating
- Transmission overheating Autostick shifts are not permitted under the illustrated conditions:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Control Module, A/T > Component Information > Service and Repair > General Information > Page 4795
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 4799
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Relays and Modules - A/T
> Transmission Control System Relay, A/T > Component Information > Locations > Page 4800
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4809
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4810
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 4811
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A >
Sep > 99 > A/T Pan Gasket - Reusable Design/Installation
Technical Service Bulletin # 21-05-99A Date: 990903
A/T Pan Gasket - Reusable Design/Installation
NUMBER: 21-05-99 Rev. A
GROUP: Transmission
DATE: Sep. 03, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5,
1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL
COVERAGE.
SUBJECT: Reusable Automatic Transmission Oil Pan Gasket
OVERVIEW: This bulletin announces availability and installation of a reusable automatic
transmission oil pan gasket.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
**1989** - 1993 (AG) Daytona
**1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - **2000** (FJ) Sebring/Avenger/Talon
1996 - **2000** (GS) Chrysler Voyager (European Market)
1995 - **2000** (JA) Cirrus/Stratus/Breeze
1996 - **2000** (JX) Sebring Convertible
**1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M**
1996 - **2000** (NS) Town & Country/Caravan/Voyager
**1995 - 2000 (PL) Neon**
**1997 - 2000 (PR) Prowler**
DISCUSSION:
A reusable silicone gasket has been developed to replace the RTV method of sealing the
automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change
intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is
recommended that this gasket be used in all applications.
NOTE:
THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES.
PARTS REQUIRED:
**1 05011113AA Gasket, Transmission Oil Pan, 31TH**
**1 05011114AA Gasket, Transmission Oil Pan, 42LE**
1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE
POLICY: INFORMATION ONLY
POLICY: Information Only
Installation Procedure
1. With oil pan removed from transmission case for routine service or transmission repair proceed
to step # 2.
2. Clean any residue from oil pan and magnet.
3. Replace O-ring and filter on bottom of valve body.
4. Using a plastic or wooden scraper, remove old RTV from transmission case rails.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-05-99A >
Sep > 99 > A/T Pan Gasket - Reusable Design/Installation > Page 4817
CAUTION:
ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD
GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING
THESE COMPONENTS.
5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails.
6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission
case. Tighten oil pan bolts to 19 Nm (165 in lbs.).
7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or
MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles.
CAUTION:
DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES
FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4822
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4823
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Technical Service Bulletins for Seals and Gaskets: > 21-07-98 > Apr
> 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4824
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep >
99 > A/T Pan Gasket - Reusable Design/Installation
Technical Service Bulletin # 21-05-99A Date: 990903
A/T Pan Gasket - Reusable Design/Installation
NUMBER: 21-05-99 Rev. A
GROUP: Transmission
DATE: Sep. 03, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-05-99 DATED MARCH 5,
1999 WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL PARTS AND MODEL
COVERAGE.
SUBJECT: Reusable Automatic Transmission Oil Pan Gasket
OVERVIEW: This bulletin announces availability and installation of a reusable automatic
transmission oil pan gasket.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
**1989** - 1993 (AG) Daytona
**1989** - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
**1989** - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - **2000** (FJ) Sebring/Avenger/Talon
1996 - **2000** (GS) Chrysler Voyager (European Market)
1995 - **2000** (JA) Cirrus/Stratus/Breeze
1996 - **2000** (JX) Sebring Convertible
**1993 - 2000 (LH) Concorde/Intrepid/New Yorker/LHS/Vision/300M**
1996 - **2000** (NS) Town & Country/Caravan/Voyager
**1995 - 2000 (PL) Neon**
**1997 - 2000 (PR) Prowler**
DISCUSSION:
A reusable silicone gasket has been developed to replace the RTV method of sealing the
automatic transmission oil pan. Due to more frequent Automatic Transmission Fluid (ATF) change
intervals and the possibility of the fluid foaming if it comes in contact with uncured RTV it is
recommended that this gasket be used in all applications.
NOTE:
THIS GASKET CAN BE REUSED UP TO THREE (3) TIMES.
PARTS REQUIRED:
**1 05011113AA Gasket, Transmission Oil Pan, 31TH**
**1 05011114AA Gasket, Transmission Oil Pan, 42LE**
1 05011115AA Gasket, Transmission Oil Pan, 41TE/AE
POLICY: INFORMATION ONLY
POLICY: Information Only
Installation Procedure
1. With oil pan removed from transmission case for routine service or transmission repair proceed
to step # 2.
2. Clean any residue from oil pan and magnet.
3. Replace O-ring and filter on bottom of valve body.
4. Using a plastic or wooden scraper, remove old RTV from transmission case rails.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > 21-05-99A > Sep >
99 > A/T Pan Gasket - Reusable Design/Installation > Page 4830
CAUTION:
ALUMINUM COMPONENTS ARE VERY SUSCEPTABLE TO METAL TRANSFER WHEN OLD
GASKET MATERIAL IS REMOVED FROM THEM. USE EXTREME CARE WHEN CLEANING
THESE COMPONENTS.
5. Apply thin coat of transmission fluid to oil pan and transmission case pan rails.
6. Orient reusable gasket properly with bolt holes and assemble oil pan and gasket to transmission
case. Tighten oil pan bolts to 19 Nm (165 in lbs.).
7. Refill transmission to the proper level with MOPAR ATF + 3 Type 7176, p/n 05010124AA, or
MOPAR ATF +4 Type 9602, p/n 05013457AA, for 1999 JA/LH/PR vehicles.
CAUTION:
DO NOT OVERFILL TRANSAXLE. DO NOT ADD OIL IF LEVEL IS BETWEEN: LOWER HOLES
FOR WARM OIL (100°F). UPPER HOLES FOR HOT OIL (180°F.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4831
Seals and Gaskets: By Symptom
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4832
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4833
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4834
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4835
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4836
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4837
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > All Other Service Bulletins for Seals and Gaskets: > Page 4838
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Seals and Gaskets, A/T >
System Information > Technical Service Bulletins > Page 4839
Seals and Gaskets: Service and Repair
Remove Oil Pump Seal
Install Oil Pump Seal
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Range Sensor (TRS) Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4844
Transmission Mode Switch: Description and Operation
PARK/NEUTRAL POSITION SWITCH INPUT (ATX)
Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to
the Powertrain Control Module (PCM) on gearshift position.
Circuit T41 connects to cavity 76 of the PCM.
TRANSMISSION RANGE SENSOR (TRS)
The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor
provides the Transmission Control Module (TCM) with information on shift lever position, contains
the transmission temperature sensor, and contains the switch for the back-up lamps.
Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the
NEUTRAL/OVERDRIVE or LOW position.
Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position.
Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE,
NEUTRAL, or LOW position.
Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL
position. This circuit is also the ground circuit for the coil side of the engine starter motor relay.
The TRS is case grounded to the transmission.
Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the
RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block.
When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1
circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive
(AWD) solenoids, if equipped.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4845
Transmission Mode Switch: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
12. Remove TRS retaining screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 4846
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4855
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4856
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4857
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4863
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 4864
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4869
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4870
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical
Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 4871
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production
Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production
Change > Page 4877
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service
Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production
Change > Page 4878
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly > Page 4881
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and
Pressure Switch Assembly > Page 4882
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4883
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4884
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4885
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 4886
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 4895
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4900
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4901
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 4902
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 4908
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
4913
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
4914
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
4915
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4916
Transmission Speed Sensor: Specifications
Input Speed Sensor .............................................................................................................................
...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor .....................................
........................................................................................................................................... 27 Nm (20
ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 4917
Transmission Speed Sensor: Locations
Transmission Control Components
Input / Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector >
Page 4920
Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 4921
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4927
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4928
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4929
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4930
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4931
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4932
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4933
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4934
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4935
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4936
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4937
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4938
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4939
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4940
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4941
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4942
Transmission Temperature Sensor/Switch: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4943
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4944
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and
Instructions > Page 4945
Transmission Control System (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission
Range Sensor
Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission
Range Sensor > Page 4948
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Description and Operation
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission
Range Sensor > Page 4949
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission
Range Sensor > Page 4950
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Circuit Operation
CIRCUIT OPERATION
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The
T54 circuit connects to cavity 54 of the TCM connector.
Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and
output speed sensor. This circuit connects to cavity 13 of the TCM connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sensors and Switches A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 4951
Transmission Temperature Sensor/Switch: Testing and Inspection
Chrysler does not provide a procedure to test the transmission temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Component Information > Adjustments
Shift Interlock: Adjustments
If ignition switch cannot be turned to the LOCK position, with shifter in PARK, an adjustment of the
Interlock System may be required. To adjust Shifter/Ignition Interlock System. follow procedure
listed below.
1. Disconnect and isolate, the battery negative (-) cable from the vehicle battery. 2. Remove
console assembly.
3. Remove the gearshift knob set screw and knob.
4. Remove the screws retaining the gearshift indicator bezel and remove bezel and indicator lamp.
5. Reinstall the gearshift knob. 6. Place shifter in PARK. 7. Turn ignition switch to the LOCK or
ACCESSORY position. If cable has lost its adjustment, manually position cable to get key into
LOCK or
ACCESSORY position. Grasp slug on interlock cable with needle-nose pliers and pull back on
cable. This will allow the ignition switch to be turned to the LOCK or ACCESSORY position.
8. Check that the interlock cable slug is completely seated into the shifter interlock lever. 9. Check
that the ignition switch is still in the LOCK or ACCESSORY position.
10. Pry up the adjuster lock on the shifter/ignition interlock cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Interlock, A/T >
Component Information > Adjustments > Page 4955
11. The spring on the interlock cable should automatically compensate for the slack in the adjuster.
12. Then snap down the interlock adjuster lock onto cable. 13. After adjusting the interlock system,
perform the inter lock system operation check.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Solenoid, A/T >
Component Information > Locations > Page 4959
Transmission Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T >
Selector Shaft, A/T > Component Information > Service and Repair
Selector Shaft: Service and Repair
REMOVAL
1. Remove shift cable from lever.
2. Loosen the lever mounting bolt. Do not remove bolt (not necessary). 3. Pull up on lever and
remove.
INSTALLATION
For installation, reverse removal procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments
Shift Cable: Adjustments
Lift and rotate the gearshift hand lever into the park (P) gate position and remove the ignition key.
This confirms the shift lever is in the gated park (P) position.
After confirming the park gate position, turn the ignition switch . If the starter will operate, the park
gate position is correct. Move the shift lever into the neutral (N) position. If the starter will operate in
this position, the linkage is properly adjusted. If the starter fails to operate in either position, linkage
adjustment is required.
1. Park the vehicle on level ground and set the parking brake. 2. Place the gearshift lever in park
(P) gate position and remove key. 3. Loosen the cable adjustment screw at the transaxle operating
lever. 4. Pull the transaxle operating lever fully forward to the park detent position. 5. Release the
park brake, then rock the vehicle to assure it is in park lock. Reset the park brake. 6. Tighten the
cable adjustment screw to 8 Nm (70 inch lbs.). Gearshift cable should now be properly adjusted. 7.
Check adjustment by using the preceding procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4967
Shift Cable: Service and Repair
REMOVAL
1. Remove cable eyelet attachment from transaxle operating lever pin.
2. Using pliers, squeeze ears of cable conduit attachment at mounting bracket and push through
hole to remove. 3. At the steering column attachment, remove the cable eyelet attachment from the
shift lever pin. 4. Using pliers, squeeze ears of cable attachment at mounting bracket then push
through hole to remove. 5. Unseat the dash grommet and remove the cable from the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Shift Linkage, A/T > Shift
Cable, A/T > Component Information > Adjustments > Page 4968
6. Remove the under instrument panel silencer.
INSTALLATION
1. Install cable into steering column attachment bracket. Verify conduit ears are fully engaged.
Verify cable does not interfere with brake pedal
actuation.
2. Attach cable eyelet fitting onto shift lever pin. 3. Insert transaxle end of cable through dash panel
hole and fully seat grommet 4. Install instrument panel silencer. Verify gearshift cable is routed
through the slot in the silencer.
CAUTION: Failure to route the cable properly at the silencer may cause brake pedal interference.
5. Attach transaxle end of cable to the mounting bracket on the transaxle. Assure the conduit
attachment ears are fully seated. 6. Attach cable eyelet fitting onto the transaxle operating lever. 7.
Complete adjustment using the gearshift cable adjustment procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Description and Operation > Front Sun Gear Assembly
Sun Gear: Description and Operation Front Sun Gear Assembly
The front sun gear assembly rides in the center of the front carrier, and is welded to the center of
two hubs that are arranged back to back. Each of the hubs are splined to a clutch. The front-most
hub is splined to the reverse clutch which turns the front sun gear when it is applied. The rearward
hub is splined to the 2-4 clutch which prevents the front sun gear from turning when it is applied.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Sun Gear > Component
Information > Description and Operation > Front Sun Gear Assembly > Page 4973
Sun Gear: Description and Operation Rear Sun Gear
The rear sun gear is located in the center of the rear carrier assembly. There are two thrust
bearings located on either side of the sun gear. When the underdrive clutch is applied, it drives the
rear sun gear through the underdrive hub and shaft.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications
Torque Converter: Specifications
Diameter ..............................................................................................................................................
................................................ 241 mm (9.48 inches)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Torque Converter >
Component Information > Specifications > Page 4977
Torque Converter: Description and Operation
The torque converter is similar in function and design to other Chrysler torque converters. The
torque converter clutch engages or disengages the turbine assembly to the impeller housing. The
application of the converter clutch is controlled electronically by the solenoid assembly and valve
body. The torque converter transmits torque from the engine crankshaft to the input shaft of the
transaxle.
The torque converter clutch may engage (under the right conditions) in either 2nd, 3rd or 4th gears.
The torque converter clutch engagement is normally very smooth and may even be undetectable
by the driver. There are two types of torque converter engagement: partial and full engagement.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 4981
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Control
System Relay, A/T > Component Information > Locations > Page 4982
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Specifications
Transmission Cooler: Specifications
Hose Clamps-All Engines ....................................................................................................................
...................................................... 2 Nm (18 in. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Specifications > Page 4986
Transmission Cooler: Description and Operation
Oil cooler is internal oil to coolant type, mounted in the radiator left tank. Rubber oil lines feed the
oil cooler and the automatic transmission. Use only approved transmission oil cooler hose. Since
these are molded to fit space available, molded hoses are recommended.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Cooler, A/T
> Component Information > Specifications > Page 4987
Transmission Cooler: Service and Repair
FLUSHING COOLERS AND TUBES
When a transaxle failure has contaminated the fluid, the oil cooler(s) must be flushed. The cooler
bypass valve in the transaxle must be replaced also. The torque converter must also be replaced
with an exchange unit. This will insure that metal particles or sludged oil are not later transferred
back into the reconditioned (or replaced) transaxle.
The recommended procedure for flushing the transaxle cooler is to use Tool 6906A Cooler Flusher.
WARNING: Wear protective eye-wear that meets the requirements of OSHA and ANSI Z87.1-1968. wear
standard industrial rubber gloves.
- Keep lighted cigarettes, sparks, flames, and other ignition sources away from the area to prevent
the ignition of combustible liquids and gases. Keep a class (B) fire extinguisher in the area where
the flusher will be used.
- Keep the area well ventilated.
- Do not let flushing solvent come in contact with your eyes or skin: if eye contamination occurs,
flush eyes with water for 15 to 20 seconds. Remove contaminated clothing and wash affected skin
with soap and water. Seek medical attention.
COOLER FLUSH USING TOOL 6906A
1. Remove cover plate filler plug on Tool 6906A, or equivalent. Fill reservoir 1/2 to 3/4 full of fresh
flushing solution. Flushing solvents are
petroleum based solutions generally used to clean automatic transmission components. DO NOT
use solvents containing acids, water, gasoline, or any other corrosive liquids.
2. Reinstall filler plug on Tool 6906A. 3. Verify pump power switch is turned OFF. Connect red
alligator clip to positive (+) battery post. Connect black (-) alligator clip to a good ground. 4.
Disconnect the cooler lines at the transmission.
NOTE: When flushing transmission cooler and lines, ALWAYS reverse flush.
5. Connect the BLUE pressure line to the OUTLET (From) cooler line. 6. Connect the CLEAR
return line to the INLET (To) cooler line 7. Turn pump ON for two to three minutes to flush cooler(s)
and lines. Monitor pressure
readings and clear return lines. Pressure readings should stabilize below 20 psi. for vehicles
equipped with a single cooler and 30 psi. for vehicles equipped with dual coolers. If flow is
intermittent or exceeds these pressures, replace cooler.
8. Turn pump OFF. 9. Disconnect CLEAR suction line from reservoir at cover plate. Disconnect
CLEAR return line at cover plate, and place it in a drain pan.
10. Turn pump ON for 30 seconds to purge flushing solution from cooler and lines. Turn pump
OFF. 11. Place CLEAR suction line into a one quart container of Mopar (R) ATF Plus 4 Type 7176
automatic transmission fluid. 12. Turn pump ON until all transmission fluid is removed from the one
quart container and lines. This purges any residual cleaning solvent from the
transmission cooler and lines. Turn pump OFF.
13. Disconnect alligator clips from battery. Reconnect flusher lines to cover plate, and remove
flushing adapters from cooler lines. 14. Check for debris on cooler and remove.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Diagrams
Transmission Range Sensor (TRS) Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Diagrams > Page 4991
Transmission Mode Switch: Description and Operation
PARK/NEUTRAL POSITION SWITCH INPUT (ATX)
Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to
the Powertrain Control Module (PCM) on gearshift position.
Circuit T41 connects to cavity 76 of the PCM.
TRANSMISSION RANGE SENSOR (TRS)
The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor
provides the Transmission Control Module (TCM) with information on shift lever position, contains
the transmission temperature sensor, and contains the switch for the back-up lamps.
Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the
NEUTRAL/OVERDRIVE or LOW position.
Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position.
Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE,
NEUTRAL, or LOW position.
Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL
position. This circuit is also the ground circuit for the coil side of the engine starter motor relay.
The TRS is case grounded to the transmission.
Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the
RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block.
When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1
circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive
(AWD) solenoids, if equipped.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Diagrams > Page 4992
Transmission Mode Switch: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
12. Remove TRS retaining screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Mode
Switch, A/T > Component Information > Diagrams > Page 4993
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5002
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5003
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 >
A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5004
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
5010
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page
5011
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
5016
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
5017
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
5018
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5024
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Technical Service Bulletins > All Other Service Bulletins for Transmission
Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5025
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
5028
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page
5029
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5030
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5031
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5032
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Position
Switch/Sensor, A/T > Component Information > Locations > Page 5033
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Pressure
Test Port, A/T > Component Information > Locations
41 TE/AE Transaxle Pressure And Cooler Ports
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5045
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5050
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5051
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5052
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 5058
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5063
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5064
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission
Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5065
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Page 5066
Transmission Speed Sensor: Specifications
Input Speed Sensor .............................................................................................................................
...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor .....................................
........................................................................................................................................... 27 Nm (20
ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Technical Service Bulletins > Page 5067
Transmission Speed Sensor: Locations
Transmission Control Components
Input / Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed Sensor Connector > Page 5070
Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission Speed
Sensor, A/T > Component Information > Diagrams > Page 5071
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5077
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5078
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5079
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5080
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5081
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5082
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5083
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5084
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5085
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5086
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5087
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5088
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5089
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5090
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5091
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5092
Transmission Temperature Sensor/Switch: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5093
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5094
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram Information and Instructions > Page
5095
Transmission Control System (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor
Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor >
Page 5098
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Description and Operation
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor >
Page 5099
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Transmission Range Sensor >
Page 5100
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Circuit Operation
CIRCUIT OPERATION
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The
T54 circuit connects to cavity 54 of the TCM connector.
Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and
output speed sensor. This circuit connects to cavity 13 of the TCM connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Transmission
Temperature Sensor/Switch, A/T > Component Information > Description and Operation > Page 5101
Transmission Temperature Sensor/Switch: Testing and Inspection
Chrysler does not provide a procedure to test the transmission temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5110
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5111
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Customer Interest for Valve Body: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5112
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5118
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5119
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Valve Body: > 21-07-98 > Apr >
98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5120
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5121
Valve Body: Specifications
Valve Body To Case Bolts ...................................................................................................................
............................................... 12 Nm (105 inch lbs.) Valve Body Bolts ..............................................
...................................................................................................................................... 5 Nm (45 inch
lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5122
A604 (41TE) 4 Speed Transaxle
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Technical Service Bulletins > Page 5123
A604 (41TE) 4 Speed Transaxle Solenoid Pack Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information
Valve Body: Description and Operation General Information
The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle
clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil
pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a
positive displacement, gear and crescent type pump. It is driven by the engine through the torque
converter hub.
The valve body has two major functions:
- Control line pressure and TCC pressure
- Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of
the manual and switch valves
Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the
pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator
valve. The valve body uses five valves along with four solenoids in the solenoid assembly to
provide control of the transaxle through all of its gear ranges. They perform all functions needed to
operate the transaxle for each of its gear ranges.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5126
Valve Body: Description and Operation Manual Valve
The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the
appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions.
The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the
middle position in both Park and Neutral. The valve moves to the right position when Reverse is
selected.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5127
Valve Body: Description and Operation Regulator Valve
The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The
pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits,
pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a
spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure.
Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve
pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring
tension working against oil pressure to keep or maintain the oil at specific pressures.
Regulated.pressure varies depending on the gear range the transaxle is operating in.
A system of sleeves and ports allows the regulator valve to work at one of three different
predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the
intake side of the oil pump.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5128
Valve Body: Description and Operation Solenoid Switch Valve
The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When
the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted
to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The
valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle
upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when
needed. The valve must return to the right before a downshift to 1st gear can occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5129
Valve Body: Description and Operation
General Information
The 41TE has a cast aluminum valve body that uses five or seven valves to control five transaxle
clutches and the torque converter clutch. It also directs pressurized fluid for lubrication. The oil
pump is the source of pressurized fluid for the valve body and solenoid assembly. The pump is a
positive displacement, gear and crescent type pump. It is driven by the engine through the torque
converter hub.
The valve body has two major functions:
- Control line pressure and TCC pressure
- Direct fluid to the clutches, torque converter, lubrication system and the solenoids by means of
the manual and switch valves
Fluid for the pump is drawn through the transaxle filter, through the valve body housing and into the
pump. The pump pressurizes the fluid and sends it back through the valve body to the regulator
valve. The valve body uses five valves along with four solenoids in the solenoid assembly to
provide control of the transaxle through all of its gear ranges. They perform all functions needed to
operate the transaxle for each of its gear ranges.
Manual Valve
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5130
The manual valve operates by mechanical shift linkage only. Its job is to send line pressure to the
appropriate hydraulic circuits and solenoids. The valve has three operating ranges or positions.
The valve shifts to the left position when OD, Drive or Low is selected. The valve shifts to the
middle position in both Park and Neutral. The valve moves to the right position when Reverse is
selected.
Regulator Valve
The regulator valve has one-function: to regulate or control-hydraulic pressure in the transaxle. The
pump supplies unregulated pressure to the regulator valve. The regulator valve controls, or limits,
pump pressure. Regulated pressure is referred to as "line pressure." The regulator valve has a
spring on one end that pushes the valve to the right. This closes a dump (vent) to lower pressure.
Closing the dump will cause oil pressure to increase. Oil pressure on the opposite end of the valve
pushes the valve to the left, opening the dump and lowering oil pressure. The result is spring
tension working against oil pressure to keep or maintain the oil at specific pressures.
Regulated.pressure varies depending on the gear range the transaxle is operating in.
A system of sleeves and ports allows the regulator valve to work at one of three different
predetermined pressure levels. The oil that is dumped by the regulator valve is directed back to the
intake side of the oil pump.
Solenoid Switch Valve
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5131
The solenoid switch valve controls the direction of line pressure from the LR/CC solenoid. When
the valve is shifted to the right, it allows the low/reverse clutch to be pressurized. When it is shifted
to the left, it directs line pressure to the TC and CC control valves to operate the TC clutch. The
valve is shifted to the right in all positions except 2nd, 3rd and 4th gear. When the transaxle
upshifts to 2nd gear, the valve moves to the left, which allows converter clutch engagement when
needed. The valve must return to the right before a downshift to 1st gear can occur.
Torque Converter Clutch Control Valve
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5132
The Torque Converter Clutch (TCC) control valve controls the back (ON) side of the torque
converter clutch. When the TCM energizes the LR/CC solenoid to engage the converter clutch
piston, the TCC control valve and torque converter control valves move to the left. The oil on the
front (OFF) side of the converter clutch piston is vented to the sump.
Line pressure enters the TCC control valve through the manual valve, and then passes through the
TCC control valve and the torque converter control valve to the back (ON) side of the converter
clutch piston. Line pressure forces the piston forward, which engages the torque converter clutch.
This action effectively connects the torque converter turbine with the impeller. Line pressure also
flows from the regulator valve, through the torque converter control valve, to the cooler and cooler
bypass, for improved fluid and transaxle cooling.
Torque Converter Control Valve
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Description and Operation > General Information > Page 5133
The torque converter control valves main responsibility is to control. hydraulic pressure applied to
the front (OFF) side of the converter clutch. Line pressure from the regulator valve is fed to the
torque converter control valve, where it passes through the valve. The torque converter control
valve reduces, or regulates, the pressure slightly. The torque converter control valve pressure is
then directed to the converter clutch control valve and to the front side of the converter clutch
piston. The pressure that is being fed to the front of the piston pushes the piston back. This
disengages the converter clutch. The oil then passes around the outside of the piston, flowing out
of the torque converter and back to the torque converter control valve. From the torque converter
control valve, the oil flows to the transaxle oil cooler and cooler bypass valve. It returns to the
transaxle as lube oil pressure.
Beginning in 1996, the torque converter control valve was modified to delete the function of
regulating the flow to the torque converter when the converter clutch is not applied. The valve
switches the direction of fluid flow when the converter clutch is applied and vents the release side
of the torque converter clutch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation
Valve Body: Service and Repair Removal and Installation
Removal
Oil Pan Bolts
Oil Pan
Oil Filter
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5136
Valve Body Attaching Bolts
NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise.
Push Park Rollers From Guide Bracket
Remove Valve Body
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5137
Valve Body Removed
Installation
To install valve body, reverse removal procedure.
CAUTION: The valve body manual shaft pilot may distort and bind the manual valve if the valve
body is mishandled or dropped.
NOTE: To ease installation of the valve body, turn the manual valve lever fully clockwise.
Guide park rod rollers into guide bracket, while shifting manual lever assembly out of the
installation position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5138
Valve Body: Service and Repair Solenoid Assembly Replacement
REMOVAL
Input Speed Sensor Removed
Remove Sound Cover
Remove Attaching Screws
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5139
Remove Solenoid Assembly
INSTALLATION
To install solenoid assembly, reverse removal procedure. Tighten screws to 12 Nm (105 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5140
Valve Body: Service and Repair 41TE 4-Speed
Transmission Range Sensor Screw
Transmission Range Sensor Removed
Manual Shaft And Rooster Comb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5141
2-4 Accumulator Plate
TRS, Manual Shaft, And 2-4 Accumulator
Valve Body Screws
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5142
Valve Body And Transfer Plate
Transfer Plate And Separator Plate
Ball Check Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Automatic Transmission/Transaxle > Valve Body, A/T >
Component Information > Service and Repair > Removal and Installation > Page 5143
Springs And Valves Location
Remove Or Install Dual Retainer Plate
TC Limit Valve And Low/Reverse Switch Valve
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications
Fluid - Differential: Capacity Specifications
Differential Oil Capacity
Capacity ...............................................................................................................................................
......................................................... 1.9L (4.0 Pints)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Capacity Specifications > Page 5149
Fluid - Differential: Fluid Type Specifications
Differential Fluid Type
Grade ...................................................................................................................................................
................................................................... API GL-5
Viscosity ..............................................................................................................................................
..................................................................... 85W-90
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Differential Assembly > Fluid - Differential > Component
Information > Specifications > Page 5150
Fluid - Differential: Service Precautions
DO NOT over fill differential beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications
Axle Shaft: Specifications
TIGHTENING SPECIFICATIONS
Caliper To Knuckle Bolts .....................................................................................................................
................................................ 31 Nm (23 ft. lbs.) Driveshaft Nut .......................................................
........................................................................................................................... 244 Nm (180 ft. lbs.)
Front Wheel Lug Nuts ..........................................................................................................................
............................................ 135 Nm (100 ft. lbs.) Knuckle To Ball Stud Nut ......................................
.............................................................................................................................. 95 Nm (70 ft. lbs.)
Tie Rod End To Knuckle ......................................................................................................................
................................................ 61 Nm (45 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 5156
Axle Shaft: Service Precautions
CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the
interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the
interconnecting shaft where the cross is installed. This twist causes a interference fit between the
interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting
shaft. This design eliminates the clearance between the cross and the interconnecting shaft
resulting in quieter operation of the driveshaft assembly. This, design though, eliminated the
capability of removing the outer C/V joint from the interconnecting shaft. For this reason the
driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft
and vibration damper) in the event of a outer C/V joint boot failure. The inner joint sealing boot will
be serviced, as on past applications, as a separate component of the driveshaft assembly.
CAUTION: Boot sealing is vital to retain special lubricants and to prevent foreign contaminants
from entering the C/V joint. Mishandling, such as allowing the assemblies to dangle unsupported,
or pulling or pushing the ends, can cut boots or damage C/V joints. During removal and installation
procedures, always support both ends of the driveshaft to prevent damage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 5157
Axle Shaft: Application and ID
Driveshaft Identification
Driveshafts and driveshaft inner and outer boots can be identified as shown. Driveshaft boot
location on the driveshaft assemblies, is determined by the number of convolutes used on the
driveshaft boot. Refer to image for the correct location of the sealing boots.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 5158
Axle Shaft: Description and Operation
GENERAL INFORMATION
Vehicles equipped with either an automatic or manual transmission uses an unequal length
driveshaft system.
Vehicles equipped with automatic transaxles use a solid short interconnecting shaft on the left side.
The right side of the vehicle uses a longer solid interconnecting shaft.
Driveshafts used on both the right and left sides of the vehicle use a tuned rubber damper weight.
The damper weight on the right side is a single clamp style damper. The damper weight on the left
side is a double clamp style damper. When replacing a driveshaft, be sure the replacement
driveshaft has the same damper weight as the original.
Both driveshaft assemblies use the same type of inner and outer joints. The inner joint of both
driveshaft assemblies is a tripod joint, and the outer joint of both driveshaft assemblies is a Rzeppa
joint. Both tripod joints and Rzeppa joints are true Constant Velocity (C/V) joint assemblies. The
inner tripod joint allows for the changes in driveshaft length through the jounce and rebound travel
of the front suspension.
On vehicles equipped with ABS brakes, the outer C/V joint is equipped with a tone wheel used to
determine vehicle speed for ABS brake operation.
The inner tripod joint of both driveshafts is splined into the transaxle side gears. The inner tripod
joints are retained in the side gears of the transaxle using a snap ring located in the stub shaft of
the tripod joint. The outer C/V joint has a stub shaft that is splined into the wheel hub and retained
by a hub nut using a nut lock and cotter pin, hub nut retention system.
NOTE: This vehicle does not use a rubber lip bearing seal as on past front wheel drive cars, to
prevent contamination of the front wheel bearing. On these vehicles, the face of the outer C/V joint
has a metal bearing shield which is pressed onto the end of the outer C/V joint housing. This
design deters direct water splash on bearing seal while allowing any water that gets in, to run out
the bottom of the bearing shield. It is important though to thoroughly clean the outer C/V joint and
the wheel bearing area in the steering knuckle before it is assembled after servicing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Specifications > Page 5159
Axle Shaft: Testing and Inspection
ON-VEHICLE INSPECTION
1. Check for grease in the vicinity of the inboard tripod joint and outboard C/V joint; this is a sign of
inner or outer joint seal boot or seal boot clamp
damage.
2. A light film of grease may appear on the right inner tripod joint seal boot; this is considered
normal and should not require replacement of the seal
boot.
NOISE AND/OR VIBRATION IN TURNS
A clicking noise and/or a vibration in turns could be caused by one of the following conditions: 1.
Damaged outer C/V or inner tripod joint seal boot or seal boot clamps. This will result in the loss
and/or contamination of the joint grease,
resulting in inadequate lubrication of the joint.
2. Noise may also be caused by another component of the vehicle coming in contact with the
driveshafts.
CLUNKING NOISE DURING ACCELERATION
This noise may be a result of one of the following conditions: 1. A torn seal boot on the inner or
outer joint of the driveshaft assembly. 2. A loose or missing clamp on the inner or outer joint of the
driveshaft assembly. 3. A damaged or worn driveshaft C/V joint.
SHUDDER OR VIBRATION DURING ACCELERATION
This problem could be a result of: 1. A worn or damaged driveshaft inner tripod joint. 2. A sticking
tripod joint spider assembly (inner tripod joint only). 3. Improper wheel alignment. Refer to Steering
and Suspension for alignment checking and setting procedures and specifications.
VIBRATION AT HIGHWAY SPEEDS
This problem could be a result of: 1. Foreign material (mud, etc.) packed on the backside of the
wheel(s). 2. Out of balance front tires or wheels. Refer to Steering and Suspension for the required
balancing procedure. 3. Improper tire and/or wheel runout. Refer to Steering and Suspension for
the required runout checking procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation
Axle Shaft: Service and Repair Removal & Installation
REMOVAL
CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing
assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a
PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 244 Nm (180 ft. lbs.).
This will ensure that the hub bearing cannot loosen.
Cotter Pin, Nut Lock And Spring Washer
1. Remove cotter pin, nut lock, and spring washer from the end of the outer C/V joint stub axle.
Loosening Front Hub Retaining Nut
2. Loosen (but do not remove) stub axle to hub/ bearing retaining nut. Loosen hub nut while vehicle
is on the floor with the brakes applied. The front
hub and driveshaft are splined together and retained by the hub nut.
3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Remove front tire and
wheel assembly from the hub.
Caliper Guide Pin Attaching Bolts
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5162
5. Remove front disc brake caliper assembly to steering knuckle guide pin attaching bolts.
Removing Disk Brake Caliper
6. Remove disc brake caliper assembly from steering knuckle. Caliper is removed by first lifting
bottom of caliper away from steering knuckle, and
then removing top of caliper out from under steering knuckle.
Correctly Supported Brake Caliper
7. Support brake caliper/adapter assembly using a wire hook. Do not support assembly by the
brake Hex hose. 8. Remove braking disc from front hub.
Removing Tie Rod End Attaching Nut
9. Remove nut attaching outer tie rod end to steering knuckle. Remove nut from tie rod end by
holding tie rod end stud with a 11/32 socket and
loosen and remove nut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5163
Tie Rod End Removal From Steering Knuckle
10. Remove the tie rod end stud from steering knuckle arm, using remover, Special Tool
MB-991113.
Wheel Speed Sensor Cable Routing Bracket
11. If equipped with antilock brakes, remove the speed sensor cable routing bracket from the
steering knuckle.
Lower Ball Joint To Steering Knuckle Attachment
12. Remove cotter pin and castle nut from stud of lower ball joint at the steering knuckle.
CAUTION: No tool is to be inserted between the steering knuckle and the lower ball joint to
separate stud of lower ball joint from the steering knuckle. The steering knuckle is to be separated
from the stud of the ball joint only using the procedure as described in Step 13.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5164
Separating Ball Joint Stud From Steering Knuckle
13. Turn steering knuckle so the front of the steering knuckle is facing as far outboard in the wheel
well as possible. Using a hammer strike steering
knuckle boss until steering knuckle separates from stud of lower ball joint. When striking steering
knuckle, care MUST be taken not to hit lower control arm or ball joint grease seal.
NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint. Driveshaft must be supported.
Separating Steering Knuckle From Outer C/V Joint
14. Pull steering knuckle assembly out and away from outer C/V joint of the driveshaft assembly.
CAUTION: When inserting pry bar between inner tripod joint and transaxle case, care must be
used to ensure no damage occurs to oil seal in transaxle case.
Disengaging Inner Tripod Joint From Transaxle
15. Support the outer end of the driveshaft assembly. Insert a pry bar between inner tripod joint and
transaxle case. Pry against inner tripod joint, until
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5165
tripod joint retaining snap ring is disengaged from transaxle side gear.
Tripod Joint Removal From Transaxle
16. Hold inner tripod joint and interconnecting shaft of driveshaft assembly. Remove inner tripod
joint from transaxle, by pulling it straight out of
transaxle side gear and transaxle oil seal. When removing tripod joint, do not let spline or snap ring
drag across sealing lip of the transaxle to tripod joint oil seal.
CAUTION: The driveshaft, when installed, acts as a bolt and secures the front hub/bearing
assembly. If vehicle is to be supported or moved on its wheels with a driveshaft removed, install a
PROPER-SIZED BOLT AND NUT through front hub. Tighten bolt and nut to 183 Nm (135 ft. lbs.).
This will ensure that the hub bearing cannot loosen.
INSTALLATION
1. Thoroughly clean spline and oil seal sealing surface, on tripod joint. Lightly lubricate oil seal
sealing surface on tripod joint with fresh clean
transmission lubricant.
2. Holding driveshaft assembly by tripod joint and interconnecting shaft, install tripod joint into
transaxle side gear as far as possible by hand. 3. Grasp inner tripod joint an interconnecting shaft.
Forcefully push the tripod joint into side gear of transaxle, until snap ring is engaged with
transaxle side gear. Test that snap ring is fully engaged with side gear by attempting to remove
tripod joint from transaxle by hand. If snap ring is fully engaged with side gear, tripod joint will not
be removable by hand.
4. Clean all debris and moisture out of steering knuckle, in the area were outer C/V joint will be
installed into steering knuckle.
Outer C/V Joint Inspection
5. Ensure that front of outer C/V joint which fits against the face of the hub and bearing is free of
debris and moisture before installing outer C/V
joint into hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5166
Steering Knuckle Installation On Outer C/V Joint
6. Slide driveshaft back into front hub. Then install steering knuckle onto the lower control arm ball
joint stud.
Lower Ball Joint To Steering Knuckle Attachment
7. Install the steering knuckle to ball joint stud castle nut. Tighten the castle nut to 95 Nm (70 ft.
lbs.).
Wheel Speed Sensor Cable Routing Bracket
8. If equipped with antilock brakes, install the speed sensor cable on the steering knuckle and
securely tighten bolt.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5167
Installing Tie Rod End Nut
Torquing Tie Rod End Nut
9. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle nut onto stud of
tie rod end. While holding stud of tie rod end
stationary, tighten tie rod end to steering knuckle nut. Using a crowfoot and 11/32 socket, tighten
the nut to 61 Nm (45 ft. lbs.).
10. Install braking disc back on hub and bearing assembly.
Disk Brake Caliper Assembly Installation
11. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding top of
caliper under top abutment on steering knuckle.
Then installing bottom of caliper against bottom abutment of steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5168
Disk Brake Caliper Bolts
12. Install caliper assembly to steering knuckle guide pin bolts. Tighten caliper assembly bolts to 31
Nm (23 ft. lbs.).
Install Washer And Hub Nut
13. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install hub nut onto
threads of stub axle and tighten nut.
Torquing Front Hub Nut
14. With vehicle brakes applied to keep braking disc from turning, tighten hub nut to 244 Nm (180
ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5169
Spring Washer, Nut Lock And Cotter Pin Installation
15. Install the spring washer, hub nut lock, and new cotter pin on end of stub axle. Wrap cotter pin
prongs tightly around the hub nut lock.
Wheel Lug Torquing Sequence
16. Install front wheel and tire assembly. Install front wheel lug nuts and tighten in the correct
sequence. Tighten lug nuts to 135 Nm (100 ft. lbs.). 17. Lower vehicle. 18. Check for correct fluid
level in transaxle assembly. Transaxle for the correct fluid level checking procedure for the type of
transaxle being
checked.
19. Set front toe on vehicle to required specification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5170
Axle Shaft: Service and Repair Outer C/V Joint Bearing Shield Service
The front hub/bearing shield on the outer C/V joint is a serviceable component of the outer C/V. If it
is damaged in use on a vehicle or during servicing of a driveshaft it can be replaced using the
following procedure.
To remove the bearing shield from the outer C/V joint, the driveshaft assemblies must be removed
from the vehicle. See Servicing Driveshaft, for the required driveshaft removal and replacement
procedure.
REMOVAL
1. Clamp driveshaft in a vise by the interconnecting shaft.
Removing Bearing Shield From Outer C/V Joint
2. Using a drift, tap around the entire edge of the bearing shield until it is removed from the outer
C/V Joint.
INSTALLATION
1. Install bearing shield by hand on outer C/V Joint so that it is installed squarely on the C/V joint.
Special Tools For Installing Bearing Shield
2. Position installer, Special Tool, C-4698-2 and handle, Special Tool, C-4698-1 on face of bearing
shield.
CAUTION: If bearing shield is not installed flush against the face of the outer C/V joint, interference
with steering knuckle will occur when driveshaft is installed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5171
Correctly Installed Bearing Shield
3. Using a hammer, drive the bearing shield on the outer C/V joint until it is flush against the front of
the outer C/V joint.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Removal & Installation > Page 5172
Axle Shaft: Service and Repair Overhaul
CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the
interconnecting shaft. These driveshafts incorporate a slight twist (helical) in the spline on the
interconnecting shaft where the cross is installed. This twist causes a interference fit between the
interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting
shaft. This design eliminates the clearance between the cross and the interconnecting shaft
resulting in quieter operation of the driveshaft assembly. This design though eliminated the
capability of removing the outer C/V joint from the interconnecting shaft. For this reason the
driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft
and vibration damper) in the event of a outer C/V joint boot failure.
NOTE: The only service which is to be performed on the driveshaft assemblies is the replacement
of the driveshaft seal boots on the inner tripod joints.
If any failure of internal driveshaft components is diagnosed during a vehicle road test or
disassembly of the driveshaft, the driveshaft will need to be replaced as an assembly.
CAUTION: Lubricant requirements and quantities are different for inner joints than for outer joints.
Use only the recommended lubricants in the required quantities when servicing driveshaft
assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly > Axle
Shaft > Component Information > Service and Repair > Page 5173
Axle Shaft: Tools and Equipment
Bearing Shield Installer C-4698
Tie Rod Remover MB-990635
Boot Clamp Installer C-4975A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Technical Service Bulletins > CV Boot - Grease Seepage
Explanation
Constant Velocity Joint Boot: Technical Service Bulletins CV Boot - Grease Seepage Explanation
NO: 03-06-98
GROUP: Differential & Drive Line
DATE: Oct. 2, 1998
SUBJECT: CV Boot Grease Seepage
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
DISCUSSION:
The right side half shaft inner CV joint boot on subject vehicles is made of a special high
temperature resistant material that can show heavy grease seepage - enough to form droplets on
the boot convolutes. Although the seepage is unsightly and will stop eventually, it does not affect
function or durability.
No replacement of the half shaft or boot is necessary for this condition. The boot should be wiped
clean as necessary.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot
Constant Velocity Joint Boot: Service and Repair Inner Tripod Joint Seal Boot
REMOVAL
To remove sealing boots from driveshafts, the driveshaft assemblies must be removed from the
vehicle. See Driveshaft for the required driveshaft removal and replacement procedure.
The inner tripod joints use no internal retention in the tripod housing to keep the spider assembly in
the housing. Therefore, do not pull on the interconnecting shaft to disengage tripod housing from
transmission stub shaft. Removal in this manner will cause damage to the inboard joint sealing
boots. 1. Remove the driveshaft requiring boot replacement from the vehicle. See Servicing
Driveshaft for the required driveshaft; removal procedure. 2. Remove large boot clamp which
retains inner tripod joint sealing boot to tripod joint housing and discard. Remove small clamp
which retains inner
tripod joint sealing boot to interconnecting shaft and discard. Remove the sealing boot from the
tripod housing and slide it down the interconnecting shaft.
CAUTION: When removing the tripod joint housing from the spider assembly, hold the bearings in
place on the spider trunions to prevent the bearings from failing away.
Spider Assembly Removal From Tripod Joint Housing
3. Slide the tripod joint housing off the spider assembly and the interconnecting shaft.
Spider Assembly Retaining Snap Ring
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5180
Spider Assembly Removal From Interconnecting Shaft
4. Remove snap ring which retains spider assembly to interconnecting shaft. Remove the spider
assembly from interconnecting shaft. If spider
assembly will not come off interconnecting shaft by hand, it can be removed by tapping spider
assembly with a brass drift. Do not hit the outer tripod bearings in an attempt to remove spider
assembly from interconnecting shaft.
5. Slide sealing boot off interconnecting shaft. 6. Thoroughly clean and inspect spider assembly,
tripod joint housing, and interconnecting shaft for any signs of excessive wear. If any parts show
signs of excessive wear, the driveshaft assembly will require replacement. Component parts of
these driveshaft; assemblies are not serviceable.
INSTALLATION
NOTE: The inner tripod joint sealing boots are made from two different types of material. High
temperature applications use silicone rubber where as standard temperature applications use
hytrel plastic. The silicone sealing boots are soft and pliable. The Hytrel sealing boots are stiff and
rigid. The replacement sealing boot MUST BE the same type of material as the sealing boot which
was removed.
Sealing Boot Installation On Interconnecting Shaft
1. Slide inner tripod joint seal boot retaining clamp, onto interconnecting shaft. Then, slide the
replacement inner tripod joint sealing boot onto the
interconnecting shaft. Inner tripod joint seal boot MUST be positioned on interconnecting shaft, so
the raised bead on the inside of the seal boot is in groove on interconnecting shaft.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5181
Spider Assembly Installation On Interconnecting Shaft
Installing Spider Assembly On Interconnecting Shaft
2. Install spider assembly onto interconnecting shaft. Spider assembly must be installed on
interconnecting shaft far enough to fully install spider
retaining snap ring. If spider assembly will not fully install on interconnecting shaft by hand, it can
be installed by tapping the spider body with a brass drift. Do not hit the outer tripod bearings in an
attempt to install spider assembly on interconnecting shaft.
Spider Assembly Retaining Snap Ring Installed
3. Install the spider assembly to interconnecting shaft retaining snap ring into groove on end of
interconnecting shaft. Be sure the snap ring is fully
seated into groove on interconnecting shaft.
4. Distribute 1/2 the amount of grease provided in the seal boot service package (DO NOT USE
ANY OTHER TYPE OF GREASE) into tripod
housing. Put the remaining amount into the sealing boot.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5182
Installing Tripod Housing On Spider Assembly
5. Align tripod housing with spider assembly and then slide tripod housing over spider assembly
and interconnecting shaft. 6. Install inner tripod joint seal boot to interconnecting shaft clamp evenly
on sealing boot.
Crimping Tool Installed On Sealing Boot Clamp
Sealing Boot Retaining Clamp Installed
7. Clamp sealing boot onto interconnecting shaft using crimper, Special Tool C-4975-A and the
following procedure. Place crimping tool C-4975-A
over bridge of clamp. Tighten nut on crimping tool C-4975-A until jaws on tool are closed
completely together, face to face.
CAUTION: Seal must not be dimpled, stretched or out of shape in any way. If seal is NOT shaped
correctly, equalize pressure in seal and shape it by hand.
8. Position sealing boot into the tripod housing retaining groove. Install seal boot retaining clamp
evenly on sealing boot.
CAUTION: The following positioning procedure determines the correct air pressure inside the inner
tripod joint assembly prior to clamping the sealing boot to inner tripod joint housing. If this
procedure is not done prior to clamping sealing boot to tripod joint housing sealing boot durability
can be adversely affected.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5183
CAUTION: When venting the inner tripod joint assembly, use care so inner tripod sealing boot does
not get punctured, or in any other way damaged. If sealing boot is punctured, or damaged in any
way while being vented, the sealing boot can not be used.
Trim Sticker Inserted For Venting Tripod Joint
9. Insert a trim stick between the tripod joint and the sealing boot to vent inner tripod joint
assembly. When inserting trim stick between tripod
housing and sealing boot ensure trim stick is held flat and firmly against the tripod housing. If this is
not done damage to the sealing boot can occur. If inner tripod joint has a Hytrel (hard plastic)
sealing boot, be sure trim stick is inserted between soft rubber insert and tripod housing not the
hard plastic sealing boot and soft rubber insert.
10. With trim stick inserted between sealing boot and tripod joint housing, position the
interconnecting shaft so it is at the center of its travel in the
tripod joint housing. Remove the trim stick from between the sealing boot and the tripod joint
housing. This procedure will equalize the air pressure in the tripod joint, preventing premature
sealing boot failure.
11. Position trilobal boot to interface with the tripod housing. The lobes of the boot must be properly
aligned with the recess's of the tripod housing. 12. Clamp tripod joint sealing boot to tripod joint,
using required procedure for type of boot clamp application.
CRIMP TYPE BOOT CLAMP
If seal boot uses crimp type boot clamp: Clamp sealing boot onto tripod housing using Crimper, Special Tool C-4975-A.
Crimping Tool Installed On Sealing Boot Clamp
- Place crimping tool C-4975-A over bridge of clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5184
Sealing Boot Retaining Clamp Installed
- Tighten nut on crimping tool C-4975-A until jaws on tool are closed completely together, face to
face.
LATCHING TYPE BOOT CLAMP
If seal boot uses low profile latching type boot clamp: Clamp sealing boot onto tripod housing using clamp locking tool, Snap-On YA3050 or an
equivalent.
Clamping Tool Installed On Sealing Boot Clamp
- Place prongs of clamp locking tool in the holes of the clamp.
Sealing Boot Clamp Correctly Installed
- Squeeze tool together until top band of clamp is latched behind the two tabs on lower band of
clamp.
13. Install the driveshaft back on the vehicle. See Servicing Driveshaft, for the required driveshaft
installation procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Axle Shaft Assembly >
Constant Velocity Joint Boot > Component Information > Service and Repair > Inner Tripod Joint Seal Boot > Page 5185
Constant Velocity Joint Boot: Service and Repair Outer C/V Joint Sealing Boot Service
CAUTION: The outer C/V joint used on this vehicle is not a serviceable joint.
CAUTION: The outer C/V joint used on this vehicle uses a new design for retaining the cross to the
interconnecting shaft. These driveshafts; incorporate a slight twist (helical) in the spline on the
interconnecting shaft where the cross is installed. This twist causes a interference fit between the
interconnecting shaft and the cross when the outer C/V joint is installed on the interconnecting
shaft. This design eliminates the clearance between the cross and the interconnecting shaft
resulting in quieter operation of the driveshaft assembly. This design though eliminated the
capability of removing the outer C/V joint from the interconnecting shaft. For this reason the
driveshafts will be serviced as a quarter shaft (outer C/V joint/sealing boot, interconnecting shaft
and vibration damper) in the event of a outer C/V joint boot failure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications > Page 5189
Wheel Bearing: Description and Operation
The rear hub and bearing assembly used on this vehicle is serviceable only as a complete
assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort
to repair it.
The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are
removable from the back of the rear hub/bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications > Page 5190
Wheel Bearing: Testing and Inspection
The rear hub and bearing assembly is designed for the life of the vehicle and should require no
maintenance. The following procedure may be used for evaluation of bearing condition.
With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral
play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings
exhibit these conditions during inspection, the hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive grease loss may also require bearing
replacement. Moderate grease loss from bearing is considered normal and should not require
replacement of the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications > Page 5191
Wheel Bearing: Service and Repair
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and
tire. 3. Remove brake drum from hub/bearing.
4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed
sensor during removal and installation of the
hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless
the speed sensor is removed first.
CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on
the tone wheel will result in false ABS cycling and corrosion of the tone wheel.
5. Remove the 4 bolts attaching the hub/ bearing to the rear axle.
CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the
hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle
by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on
the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in
noise or failure of the bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Bearing >
Component Information > Specifications > Page 5192
6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or
equivalent and following procedure to press the
hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and
against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of
Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the
bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should
be against and supported by the axle plate when pressing the wheel bearing out of the axle. If
Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the
flashing from the hole until tool fits properly.
d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or
equivalent. Tighten bolt against Special Tool 8214-1
or equivalent.
e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special
Tool 8214-1 or equivalents.
Removing Rear Hub/Bearing From Axle
7. Remove the hub/bearing from the rear axle and brake support plate.
INSTALL
1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2.
Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3.
Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle.
4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the
proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Drive Axles, Bearings and Joints > Wheel Hub > Axle Nut >
Component Information > Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Flex Plate > Component Information > Specifications
Flex Plate: Specifications
TORQUE SPECIFICATIONS
Drive Plate-to-Crankshaft Bolts ...........................................................................................................
..................................................... 95 Nm (70 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5210
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > Customer Interest for
Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5211
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5217
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Technical Service Bulletins > All Technical Service
Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder > Page 5218
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page
5221
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page
5222
Control Module: Locations Power Distribution Center
Junction Block
Power Distribution Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Locations > Transmission Control Module > Page
5223
Fuse Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5226
Control Module: Diagrams Control Module, A/T
Part 1 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5227
Part 2 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5228
Part 3 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5229
Part 4 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5230
Part 5 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5231
Part 6 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5232
Part 7 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5233
Part 8 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5234
Part 9 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Diagrams > Power Control Module > Page 5235
Part 11 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5238
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5239
Control Module: Description and Operation TCM Inputs
General Information
GENERAL INFORMATION
The TCM receives input information and continuously processes this information through its logic
circuits to perform all of the control functions that it is designed to perform. However, some of these
control functions are internal to the TCM, while other control functions are performed when the
TCM provides some type of output signal to another control device or module. The following is a
description of TCM input sensors and output devices.
The TCM uses various inputs to determine when to upshift or downshift and when to engage or
disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous
feedback data for controlling shift quality. Without any input, the TCM has no way to determine the
state of the transaxle and cannot control its operation as designed.
Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other
components through the CCD Bus.
DIRECT (HARD-WIRED) TCM INPUTS
- Battery Feed
- Ignition RUN Signal
- Cranking Signal
- Throttle Position Sensor (TPS) Signal
- Engine speed signal (Distributor or DIS Crankshaft Position Sensor)
- Input Speed Sensor Signal
- Output Speed Sensor Signal
- Transmission Range Sensor**(Includes Transmission Temperature Sensor)
- Transmission Control Relay (Switched Battery)
- L/R Pressure Switch Signal
- 2-4 Pressure Switch Signal
- O/D Pressure Switch Signal
- Park/Neutral Position Switch*
- PRNDL Switch*
- Torque Reduction Request Line (TRD Link)
INDIRECT (CCD BUS) TCM INPUTS
- Target Idle Speed
- Engine Coolant Temperature (ECT) Sensor
- Battery Temperature Sensor*
- Brake Switch
- Engine and Body Identification
- Engine Speed (Verifies Direct Input Engine Speed Signal)
- Speed Control ON/OFF Switch
- Speed Control Set Speed
- A/C Clutch Engagement
- Vehicle Identification Number (VIN)
- Manifold Absolute Pressure (MAP) Sensor
- Torque Reduction Confirmation Response
- Relative Throttle Position (Beginning in 1998)
*: UP TO 1995 **: BEGINNING IN 1996
Battery and Ignition (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5240
BATTERY
A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced
and also fed to the contact side of the Transmission Control Relay. On vehicles with an original
TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the
adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or
road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated
per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in
memory; therefore, a quick learn or road test is not necessary.
IGNITION
When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START
(CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above
approximately 26 volts or below 8 volts, the TCM automatically powers down which results in
limp-in symptoms.
Throttle Position Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5241
The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift
quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5
volt supply and ground for the sensor. Target idle speed is compared against actual engine speed
to determine the learned TPS value for closed throttle idle. This is done to correct for differences in
system voltage and sensor tolerances.
If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by
substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier
vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts
that are vehicle speed dependent.
NOTE: Refer to TSB 18-13-94 if erratic shifting is evident.
Input Speed Sensors and Output Speed Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5242
The input speed sensor provides information to the TCM on how fast the torque converter turbine is
spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing.
The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input
clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is
induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this
information as input shaft rpm. This information is also compared to the output shaft speed and the
engine speed signal to determine the following:
- Planetary gears operating ratio
- Torque converter clutch slippage
- Torque converter element speed ratio
The output speed sensor is located on the same side of the transaxle case as the input speed
sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal
from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the
output speed sensor signal is received by the TCM, the signal is compared to the input speed
signal to determine gear ratio, detect clutch slippage, etc.
Pressure Switches (Hard-Wired)
The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack
Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits.
The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at
approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists
or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic
pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the
shift lever electrical signal is incorrect.
Transmission Temperature Sensor (Hard-Wired) (Beginning 1996)
The Transmission Temperature Sensor is used to monitor the temperature of the transmission
fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based
on the resistance value of the temperature sensor located in the Transmission Range Sensor
(TRS). The primary temperature inputs used by the TCM are the Transmission Temperature
Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be
running to get accurate temperature readings.
NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral
position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position
switch.
If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination
of inputs. The calculated fluid temperature is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5243
continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF.
On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the
vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a
value between the battery temperature and engine coolant temperature signals received from the
PCM over the CCD Bus.
The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The
temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS,
non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a
heat transfer equation that uses engine coolant temperature, battery/ambient temperature and
extended time off (if known) at start up.
Transmission Shift Scheduling
Once the engine is started, the TCM updates the transmission oil temperature based on the
following to determine an estimated oil temperature during vehicle operation (if a calculated oil
temperature is being used):
- Torque converter slip speed
- Vehicle speed
- Engine coolant temperature
- Battery/ambient temperature
Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal
operation. However, if a transmission oil cooler is added, a transmission is overfilled, a
transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the
calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be
inappropriate for the current conditions.
The key highlights of the various shift schedules are as follows:
Extreme Cold: Oil temperature at start up below -16° F.
- Goes to "Cold" schedule above - 12°F oil temperature
- Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent
shifts)
Cold: Oil temperature at start up above - 12 ° F and below 36°F
- Goes to "Warm" schedule above 40° F oil temperature
- Delayed 2-3 upshift (approximately 22 - 31 MPH)
- Delayed 3-4 upshift (45 - 53 MPH)
- Early 4-3 coastdown shift (approximately 30 MPH)
- Early 3-2 coastdown shift (approximately 17 MPH)
- High speed 4-2, 3-2, 2-1 kickdown shifts are prevented
- No EMCC
Warm: Oil temperature at start up above 36° F and below 80° F
- Goes to "Hot" schedule above 80°F oil temperature
- Normal operation (upshift, kick-downs and coast-downs)
- No EMCC
Hot: Oil temperature at start up above 80° F
- Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY)
- Normal operation (upshifts, kick-downs and coast-downs)
- Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH)
Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F
- Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH
97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F
- Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH)
- Delayed 3-4 upshift (41 - 48 MPH)
- 3rd gear FEMCC from 30 - 48 MPH
- 3rd gear PEMCC from 27 - 31 MPH
Super Overheat: 97 MY - Oil temperature above 240°F
- Goes back to "Overheat" below 240 ° F oil temperature
- All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
96 and prior MY - Oil temperature above 260°F
- Goes back to "Overheat" below 260 ° F oil temperature
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5244
- All "Overheat" shift schedule features apply
- 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
Causes for operation in the wrong temperature shift schedule:
Extreme Cold or Cold shift schedule at start up:
- Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only)
- Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only)
- Defective PCM (calculated oil temperature vehicles only)
- Defective sensor circuit (TRS equipped only)
Overheat or Super Overheat shift schedule after extended operation:
- Operation in city traffic or stop-and-go traffic
- Engine idle speed too high - Stuck AIS motor
- Aggressive driving in low gear
- Trailer towing in OD gear position (use "3" position if frequent shifting occurs)
- Cooling system failure causing engine to operate over 230° F
- Engine coolant temperature stays low too long - If engine coolant temperature drops below 150°
F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will
cause the transmission to overheat.
- A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC
disengaged will cause the transmission to overheat.
- Transmission fluid overfilled (TRS equipped only)
- Transmission cooler or cooler lines restricted (TRS equipped only)
- Defective sensor circuit (TRS equipped only)
Engine Speed (Hard-Wired and CCD Broadcast)
The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor,
as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is
required to provide immediate information for use by the TCM control logic. The CCD engine speed
data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid.
MAP Sensor (CCD Broadcast)
The MAP Sensor provides engine load input directly to the PCM, which determines engine torque
load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The
TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades.
Engine Idle Speed (Hard-Wired and CCD Broadcast)
The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle
speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual
engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle.
Brake Switch (CCD Broadcast)
The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque
converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control
when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5245
Battery/Ambient Temperature Sensor (CCD Broadcast)
The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD
broadcast information is used to control charging system, engine and transaxle operation. The
TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM
detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of
the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the
Battery Temperature signal along with engine coolant temperature to calculate the temperature.
Shift Lever Position (SLP)
The TCM identifies the position of the manual lever by comparing the current switch positions of
the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The
primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle
with the presence of an invalid or transition input code. The SLP logic function screens the input
codes from the switches and provides an SLP output signal to control actual gear selection.
Inputs include the codes indicated by the TRS current shift lever position, pressure switch
indications and speed ratio data from the input to most of the other functions in the TCM.
The identified position is stored in memory. The current switch position is determined by sensing
the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM
receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the
Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD
Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on
the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated.
CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with
sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is
a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse
but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed
data will not agree with the expected results for shift lever position = "OD." Therefore, it is important
to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes.
It is extremely important that accurate shift lever position data be available to the TCM. The
accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test,
performed on the DRB Scan Tool, passes without fail.
Torque Management Signal (CCD Broadcast)
With some engines, the TCM sends a direct input, torque management request signal to: the PCM.
This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque
management request signal is used in order to reduce the torque applied in the 2-4 and OD
clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel
injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine
during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a
very short time period. The PCM sends a confirmation of the request to the TCM over the CCD
Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually
be set.
The torque management signal is basically a 9-volt supply to the PCM. A torque management
request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is
called TRD link, which stands for "Torque Reduction Link."
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5246
PRNDL Switch (Hard-Wired)
NOTE: Used up to 1995 (Early 96 NS)
The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along
with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The
TCM uses this input to determine what gear range and shift pattern to use.
Park/Neutral Position Switch (Hard-Wired)
NOTE: Used up to 1995 and early 96 NS
The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and
Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position
Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both
switches must be closed to operate the back-up lamps.
Transmission Range Sensor (Hard-Wired)
The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission
Range Switch that are found on vehicles prior to the 1996
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5247
MY. This sensor allows for accurate transaxle gear position identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5248
Control Module: Description and Operation TCM Outputs
General Information
The TCM directly controls the following:
- Transmission Control Relay
- Solenoid pack
- Torque management requests to the PCM
Additionally, the TCM broadcasts the following information over the CCD Bus for use by other
vehicle control systems (Indirect Outputs):
- Communication with the DRB Scan Tool for diagnostics
- Shift lever position to the BCM
- Shift lever position to the shift lever display
- Transmission oil temperature to the PCM in order to activate the cooling fans
- Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus
- Limp - in Status
- Transmission Temperature
- In-gear position
NOTE: MIL request is from the PCM.
Transmission Control Relay
The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal
electronic circuits are all working properly. If the self-test results are good, then the TCM sends
battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts,
which then supply battery voltage to the TCM, the four solenoids and the three pressure switches
in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to
the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then
stored in memory. The Transmission Control Relay is located in various places depending on the
vehicle model.
Solenoid and Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5249
When the Transmission Control Relay contact points are closed, the solenoid assembly receives
electrical power. The TCM can then operate the solenoids, as determined by its programming. The
relay provides power to all four solenoids through a single wire. This means that all the solenoids
have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids,
however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is
needed.
The assembly is mounted to the outside of the transaxle case, under a sound shield protective
cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel
plate. There are also small solenoid valve filters used to protect the valves from contamination.
These filters are not replaceable. If the valve body and solenoid pack have been heavily
contaminated, the solenoid pack should be closely inspected to determine if it should be replaced.
The solenoid pack is not a serviceable unit.
The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control
Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to
four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the
solenoid/valves is that they directly control the application of a clutch. In other electronically
controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through
normal hydraulic valving. The solenoid assembly also contains pressure switches that feed
information to the TCM.
Vehicle Speed Signal
The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor
signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output
speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM.
The PCM receives this signal and converts it to a signal that can be used by the Body Control
Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent
over the CCD Bus.
Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5250
On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive
lockout function operated by a button on the instrument panel. The lockout feature makes driving
smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the
transaxle may shift in and out of overdrive, causing unnecessary shifting.
NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ
vehicles use a momentary contact switch.
Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and
provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to
normal operation and turn off the overdrive lockout lamp.
With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If
the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3
upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an
earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the
overdrive lockout switch or selection of the "3" position.
Electronic Pinion Factor
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRB Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration:
- If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when moving
- Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification
Use the following procedures to set the electronic pinion factor using the DRB Scan Tool:
- Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will
display the current tire size.
- If the tire size is incorrect, depress the Enter key and then select the correct size.
- Depress the Page Back key to exit the reset procedure.
Shifter/Ignition Interlock
The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the
automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The
interlock system locks the floor mounted shift lever into the PARK position whenever the ignition
switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the
shifter is unlocked and will move into any position. The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK
position.
Shift Position Indicator
The shifter position indicator is located in the instrument cluster. The shifter position indicator
outlines with a box the gear position the transaxle manual valve lever is in.
The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM
on the position of the transaxle manual valve lever. The TCM receives the switch signal and
processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the
CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster.
Autostick
Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When
the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using
before Autostick was activated. Moving the shifter to the left (towards the driver) causes a
downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument
cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while
in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift
schedule.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Description and Operation > General Information >
Page 5251
Automatic Overrides
Some shifts are executed automatically or prevented Automatic shifts will occur under the
illustrated conditions:
Additionally, under certain circumstances, the TCM may take over and override the autostick
features, for example, under the following conditions:
- Autostick switch input errors
- Error overspeed
- Engine overheating
- Transmission overheating Autostick shifts are not permitted under the illustrated conditions:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Control Module, A/T > Component Information > Service and Repair > General Information > Page
5254
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations
Transmission Control System Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5258
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Relays and Modules - Transmission and Drivetrain > Relays
and Modules - A/T > Transmission Control System Relay, A/T > Component Information > Locations > Page 5259
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams
Transmission Range Sensor (TRS) Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5265
Transmission Mode Switch: Description and Operation
PARK/NEUTRAL POSITION SWITCH INPUT (ATX)
Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to
the Powertrain Control Module (PCM) on gearshift position.
Circuit T41 connects to cavity 76 of the PCM.
TRANSMISSION RANGE SENSOR (TRS)
The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor
provides the Transmission Control Module (TCM) with information on shift lever position, contains
the transmission temperature sensor, and contains the switch for the back-up lamps.
Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the
NEUTRAL/OVERDRIVE or LOW position.
Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position.
Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE,
NEUTRAL, or LOW position.
Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL
position. This circuit is also the ground circuit for the coil side of the engine starter motor relay.
The TRS is case grounded to the transmission.
Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the
RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block.
When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1
circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive
(AWD) solenoids, if equipped.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5266
Transmission Mode Switch: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
12. Remove TRS retaining screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Mode Switch, A/T > Component Information > Diagrams > Page 5267
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5276
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5277
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5278
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range
Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range
Sensor - Production Change > Page 5284
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range
Sensor - Production Change > Page 5285
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 5290
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 5291
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Transmission Position Switch/Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE
Delayed Gear Engagement > Page 5292
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 5298
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Technical Service Bulletins >
All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99 > Feb > 99 > Transmission Range Sensor Production Change > Page 5299
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly > Page 5302
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Transmission
Solenoid and Pressure Switch Assembly > Page 5303
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5304
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5305
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5306
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component Information > Locations > Page 5307
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control >
Page 5316
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
5321
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
5322
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Customer
Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page
5323
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of
Cruise Control > Page 5329
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 5334
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 5335
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 5336
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5337
Transmission Speed Sensor: Specifications
Input Speed Sensor .............................................................................................................................
...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor .....................................
........................................................................................................................................... 27 Nm (20
ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Technical Service Bulletins > Page 5338
Transmission Speed Sensor: Locations
Transmission Control Components
Input / Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed
Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Input (Turbine) Speed
Sensor Connector > Page 5341
Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Speed Sensor, A/T > Component Information > Diagrams > Page 5342
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5348
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5349
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5350
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5351
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5352
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5353
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5354
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5355
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5356
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5357
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5358
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5359
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5360
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5361
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5362
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5363
Transmission Temperature Sensor/Switch: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5364
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5365
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Diagrams > Diagram
Information and Instructions > Page 5366
Transmission Control System (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
> Transmission Range Sensor
Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
> Transmission Range Sensor > Page 5369
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Description and Operation
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
> Transmission Range Sensor > Page 5370
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
> Transmission Range Sensor > Page 5371
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Circuit Operation
CIRCUIT OPERATION
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The
T54 circuit connects to cavity 54 of the TCM connector.
Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and
output speed sensor. This circuit connects to cavity 13 of the TCM connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Sensors and Switches - Transmission and Drivetrain > Sensors
and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component Information > Description and Operation
> Page 5372
Transmission Temperature Sensor/Switch: Testing and Inspection
Chrysler does not provide a procedure to test the transmission temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Capacity Specifications
Fluid - Transfer Case: Capacity Specifications
Power Transfer Unit .............................................................................................................................
........................................................ 1.2L (2.4 Pints)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Capacity Specifications > Page 5378
Fluid - Transfer Case: Fluid Type Specifications
Power Transfer Unit
Viscosity ..............................................................................................................................................
.............................................................. SAE 85W-90
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transfer Case > Fluid - Transfer Case > Component
Information > Specifications > Page 5379
Fluid - Transfer Case: Service Precautions
DO NOT over fill transfer case beyond normal fluid level. Fluid foaming and damage may occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Actuators and Solenoids Transmission and Drivetrain > Actuators and Solenoids - A/T > Shift Solenoid, A/T > Component Information > Locations >
Page 5386
Transmission Solenoid Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder >
Page 5397
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > Customer Interest for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed Shifts/Shudder >
Page 5398
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed
Shifts/Shudder
Technical Service Bulletin # 21-03-98 Date: 980213
A/T - MIL ON/Delayed Shifts/Shudder
NO: 21-03-98
GROUP: Transmission
DATE: Feb. 13, 1998
SUBJECT: Transaxle Desensitization To Intermittent Faults/Driveability Improvements
MODELS:
1998 (FJ) Avenger/Sebring/Talon 1998 (GS) Chrysler Voyager (European Market) 1998 (JA)
Cirrus/Stratus/Breeze 1998 (JX) Sebring Convertible 1998 (LH) Concorde/Intrepid 1998 (NS) Town
& Country/Caravan/Voyager
NOTE:
THIS INFORMATION APPLIES TO VEHICLES BUILT PRIOR TO DEC. 13, 1997 (MDH 1213XX)
WITH A 41TE/AE OR 42LE TRANSAXLE.
DISCUSSION:
New software has been released to address the following:
All models:
Be more tolerant of intermittent conditions that may cause MIL illumination, limp-in or DTC
generation. Following is a list of symptom/conditions made more fault tolerant:
1. Corrects an error in extreme cold temperatures -27 C (-16 F) degrees or below. This allowed the
transaxle to switch to the cold schedule too quickly. This may cause MIL illumination and limp-in
conditions with associated DTC's due to slower than expected response from the fluid.
2. Reduce excessively long (more than 3 second) 3-2 shifts as the vehicle is coasting or braking to
a stop with 4 C (40 F) degree or below fluid temperature. The driver may experience slight engine
flare accelerating from a stop and/or sluggish acceleration due to the transaxle still being in 2nd
gear instead of 1st.
On FJ/GS/JA/JX/NS models:
1. Improves the shift schedule while towing in hilly conditions. The driver may describe this
condition as being in the wrong gear or delayed upshifts after cresting a hill.
On NS/GS models:
1. Reduces a shudder condition that may be experienced during a light to moderate throttle 1-2
upshift with -1 C (30 F) degree fluid temperature or higher. This condition can be experienced more
frequently as the fluid becomes hotter.
2. Reduces a shudder condition that may be experienced during a 2-3 upshift just after a 3-2 or 4-2
kick-down.
On FJ 2.0L (non turbo) models:
1. Reduces a closed or light throttle engine sag experienced between 9 and 27 mph with 7 C (45 F)
degree or below fluid temperature.
DIAGNOSIS:
Using the Mopar Diagnostic System (MDS) or the Diagnostic Scan Tool (DRB III) with the
appropriate Diagnostic Procedures Manual, verify all engine/transmission systems are functioning
as designed. If unrelated Diagnostic Trouble Codes (DTC's) are present, record them on the repair
order and repair as necessary before proceeding further with this bulletin. If DTC's that relate to the
above conditions are present or if the customer describes any of the conditions listed above,
perform the Repair Procedure.
NOTE:
WHENEVER A TRANSMISSION CONTROL MODULE (TCM) IS REPLACED DUE TO FAILURE,
THE SOFTWARE OF THE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed
Shifts/Shudder > Page 5404
REPLACEMENT CONTROLLER SHOULD BE VERIFIED FOR THE LATEST REVISION LEVEL.
USE THE FLASH PROCEDURE TO UPDATE REPLACED CONTROLLERS AS NECESSARY.
EQUIPMENT/PARTS REQUIRED:
1 CH6000 Scan Tool (DRB III)
1 CH7035 General Purpose Interface Bus Cable (GPIB)
1 CH7000/7001 J1962 Cable
1 CH7010 J1962 MMC Cable
1 04669020 Label - Authorized Software Update
1 04275086 Label - Authorized Modification
NOTE:
THE MDS AND DRB III ARE REQUIRED TO PERFORM PART OF THIS REPAIR AND THE
SYSTEM MUST BE OPERATING WITH RELEASE 21 OR HIGHER AND TIL CD RELEASE 1151
OR HIGHER MUST BE INSTALLED.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-19-50-93 0.5 Hrs.
FAILURE CODE: FM - Flash Module
Repair Procedure
This bulletin involves selectively erasing and reprogramming the Transmission Control Module
(TCM) with new software (calibration changes).
1. Connect the MDS (Mopar Diagnostic System) and DRB III (Scan Tool) to the vehicle and power
them up.
2. Use the arrow keys and select # 2 MDS DIAGNOSTICS on the DRB III MAIN MENU Screen.
3. Use the arrow keys and select DIAGNOSTIC MENU on the MDS, then press NEXT MENU.
4. Use the arrow keys and select VEHICLE CONTROLLER PROGRAMMING on the MDS, then
press NEXT MENU.
5. Use the arrow keys and select PROGRAMMING OF ALL OTHER CONTROLLERS USING MDS
& DRB III on the MDS, then press NEXT MENU.
6. Follow the steps presented on the MDS and DRB III which will allow the DRB III to obtain the
current part number of the TCM.
7. The MDS will display the part number of the TCM on the vehicle and the appropriate
replacement part number, then press NEXT MENU to begin programming.
If the TCM on the vehicle has already been updated or programmed, a NO UPDATES AVAILABLE
message will be displayed. Check the part number of the TCM on the vehicle and compare it to the
part number displayed. If the TCM has already been updated, then another condition exists that will
require further diagnosis and repair.
8. The MDS and DRB III will prompt for any operator action needed during the remainder of the
programming process.
NOTE:
THE FOLLOWING STEPS ARE REQUIRED BY LAW.
9. Type the necessary information on the 1Authodzed Software Update Label" p/n 04669020
(Figure 1). Attach the label to the TCM and cover the label with the clear plastic overlay.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Control Module: > 21-03-98 > Feb > 98 > A/T - MIL ON/Delayed
Shifts/Shudder > Page 5405
10. Type the necessary information on the "Authorized Modification Label" p/n 04275086 and
attach the label near the VECI Label (Figure 2).
11. After the flash update is complete, verify the repair by attempting to duplicate the condition
experienced by the customer. If DTC(s) or 1 trip faults can be set, further diagnosis and repair will
be required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module
Transmission Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 5408
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 5409
Control Module: Locations Power Distribution Center
Junction Block
Power Distribution Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Locations >
Transmission Control Module > Page 5410
Fuse Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module
Power Control Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5413
Control Module: Diagrams Control Module, A/T
Part 1 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5414
Part 2 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5415
Part 3 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5416
Part 4 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5417
Part 5 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5418
Part 6 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5419
Part 7 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5420
Part 8 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5421
Part 9 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Diagrams >
Power Control Module > Page 5422
Part 11 Of 11
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information
Control Module: Description and Operation General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5425
The Transmission Control Module (TCM) is the controlling unit for all electronic operations of the
transaxle. The TCM receives information from several inputs, and selects the operational mode of
the transaxle. Some of the inputs are used only by the TCM, while others are shared with other
control modules on the CCD Bus.
Shift schedule logic, which is programmed into the TCM, selects the appropriate shift schedules for
operating conditions. This is to determine the desired gear range the transaxle must be operated
in. The actual shift points within each shift schedule have been predetermined for the best
transaxle operation, and are stored in the TCM's ROM memory.
Once a TCM is installed during service, the following procedures must be performed:
- Quick Learn Procedure - Allows the transmission control module to learn the characteristics of the
vehicle
- Electronic Pinion Factor Procedure - Reprograms the TCM to compensate for different tire sizes
and final drive ratios on 1993 and newer vehicles
The quick learn procedure is necessary to learn Clutch Volume Index (CVI). The TCM must learn
the CVI of the transaxle if it is to be fully adaptive. The quick learn procedure simply speeds up the
TCM learning process. The vehicle must still be driven and shifted several times in each gear
range during the road test. This will fully utilize the TCM's adaptive memory capability. The quick
learn procedure is accessed through transaxle diagnosis and performed by the DRB Scan Tool.
NOTE: The quick learn procedure works only on version 10 (or later) TCM's. Look at the module
display on the DRB III scan tool
Emission regulations require the use of two labels after a flash update:
- Emission Modification Label
- Emission Part Number Modification Label
The following provides information on TCM identification and flash programming application:
1989 - 92 Original controllers were non-finned and are non-flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
1993 - 95 Original controllers were finned with four heat sinks and are flashable
- Replacement controllers have fins with four heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- Requires the use of Miller CH 5500 flash kit
NOTE: Use TSB 18-24-95 to identify the few controller part numbers that are not flashable. This
TSB also lists the 1990 vehicles that require a wiring modification to pin 49.
1996 Original controllers were finned with seven heat sinks and are flashable
- Replacement controllers have fins with seven heat sinks and are flashable
- Unique communications on CCD Data Bus for these year models
- DOES NOT require the use of Miller CH5500 flash kit - Connection is made under the dash in the
common DLC
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5426
Control Module: Description and Operation TCM Inputs
General Information
GENERAL INFORMATION
The TCM receives input information and continuously processes this information through its logic
circuits to perform all of the control functions that it is designed to perform. However, some of these
control functions are internal to the TCM, while other control functions are performed when the
TCM provides some type of output signal to another control device or module. The following is a
description of TCM input sensors and output devices.
The TCM uses various inputs to determine when to upshift or downshift and when to engage or
disengage the Torque Converter Clutch (TCC). The TCM also uses these inputs for continuous
feedback data for controlling shift quality. Without any input, the TCM has no way to determine the
state of the transaxle and cannot control its operation as designed.
Some of the inputs to the TCM are direct, or hard-wired inputs, while others are shared with other
components through the CCD Bus.
DIRECT (HARD-WIRED) TCM INPUTS
- Battery Feed
- Ignition RUN Signal
- Cranking Signal
- Throttle Position Sensor (TPS) Signal
- Engine speed signal (Distributor or DIS Crankshaft Position Sensor)
- Input Speed Sensor Signal
- Output Speed Sensor Signal
- Transmission Range Sensor**(Includes Transmission Temperature Sensor)
- Transmission Control Relay (Switched Battery)
- L/R Pressure Switch Signal
- 2-4 Pressure Switch Signal
- O/D Pressure Switch Signal
- Park/Neutral Position Switch*
- PRNDL Switch*
- Torque Reduction Request Line (TRD Link)
INDIRECT (CCD BUS) TCM INPUTS
- Target Idle Speed
- Engine Coolant Temperature (ECT) Sensor
- Battery Temperature Sensor*
- Brake Switch
- Engine and Body Identification
- Engine Speed (Verifies Direct Input Engine Speed Signal)
- Speed Control ON/OFF Switch
- Speed Control Set Speed
- A/C Clutch Engagement
- Vehicle Identification Number (VIN)
- Manifold Absolute Pressure (MAP) Sensor
- Torque Reduction Confirmation Response
- Relative Throttle Position (Beginning in 1998)
*: UP TO 1995 **: BEGINNING IN 1996
Battery and Ignition (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5427
BATTERY
A fused, direct battery feed to the TCM is used for continuous power. The battery feed is spliced
and also fed to the contact side of the Transmission Control Relay. On vehicles with an original
TCM, built before 1995, if the TCM loses battery voltage for a period of time, it may lose the
adaptive memory. Transaxle characteristics may be relearned by performing the quick learn or
road test procedures. If battery power is lost to the TCM on vehicles built before 1995 but updated
per TSB 18-24-95 (or vehicles built after 1995), then all adaptive learn values will be retained in
memory; therefore, a quick learn or road test is not necessary.
IGNITION
When the ignition switch is turned to the OFF (column un-lock), the RUN (ON), or the START
(CRANK) positions, the TCM is activated and looks at incoming voltage. If the voltage is above
approximately 26 volts or below 8 volts, the TCM automatically powers down which results in
limp-in symptoms.
Throttle Position Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5428
The Throttle Position Sensor (TPS) is used by the TCM to help determine shift points and shift
quality Additionally, the TPS output is spliced to the PCM for fuel control. The PCM provides a 5
volt supply and ground for the sensor. Target idle speed is compared against actual engine speed
to determine the learned TPS value for closed throttle idle. This is done to correct for differences in
system voltage and sensor tolerances.
If the TCM detects a faulty TPS signal, it provides continued operation of the transaxle by
substituting a throttle position default value near 1/3 full open, or 25 degrees (for 1997 and earlier
vehicles). In 1998 relative throttle begins. This substitution value results in upshifts and downshifts
that are vehicle speed dependent.
NOTE: Refer to TSB 18-13-94 if erratic shifting is evident.
Input Speed Sensors and Output Speed Sensor (Hard-Wired)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5429
The input speed sensor provides information to the TCM on how fast the torque converter turbine is
spinning. The sensor is located on the front side of the transaxle case, close to the bellhousing.
The Input Speed Sensor is a two wire magnetic pickup sensing device. As the teeth of the input
clutch hub pass by the sensor coil and magnet, an AC voltage proportional to shaft rotation is
induced into the coil of the sensor. This AC signal is sent to the TCM. The TCM interprets this
information as input shaft rpm. This information is also compared to the output shaft speed and the
engine speed signal to determine the following:
- Planetary gears operating ratio
- Torque converter clutch slippage
- Torque converter element speed ratio
The output speed sensor is located on the same side of the transaxle case as the input speed
sensor, but much closer to the end of the transaxle. The output speed sensor generates a signal
from the rotation of the rear planetary carrier park pawl lugs passing by the sensor. When the
output speed sensor signal is received by the TCM, the signal is compared to the input speed
signal to determine gear ratio, detect clutch slippage, etc.
Pressure Switches (Hard-Wired)
The Low/Reverse, Overdrive and 2-4 pressure switches are all located in the Solenoid Pack
Assembly. These switches indicate to the TCM if hydraulic problems occur in the clutch circuits.
The pressure switches do not tell the TCM how much pressure is in the circuit, though they open at
approximately 11 psi and close at approximately 23 psi. They simply indicate that pressure exists
or does not exist. This information verifies that the solenoids are operating correctly and if hydraulic
pressure is available to determine if a loss of pump prime has occurred or to engage 1st gear if the
shift lever electrical signal is incorrect.
Transmission Temperature Sensor (Hard-Wired) (Beginning 1996)
The Transmission Temperature Sensor is used to monitor the temperature of the transmission
fluid. Power for the sensor is supplied by the TCM. Actual transmission fluid temperature is based
on the resistance value of the temperature sensor located in the Transmission Range Sensor
(TRS). The primary temperature inputs used by the TCM are the Transmission Temperature
Sensor, Battery Temperature Sensor, ECT Sensor and in-gear run time. The engine must be
running to get accurate temperature readings.
NOTE: A transmission will either have a TRS or a combination PRNDL switch and park/neutral
position switch. A transmission with a TRS cannot have a PRNDL switch or park/neutral position
switch.
If the sensor fails, the TCM defaults to a fluid temperature which is calculated from a combination
of inputs. The calculated fluid temperature is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5430
continually updated and retained in memory for 20 minutes after the Ignition Switch is turned OFF.
On vehicles equipped with a BCM, the calculated temperature is retained for four hours. When the
vehicle is started after an extended OFF time, the calculated fluid temperature is reinitialized at a
value between the battery temperature and engine coolant temperature signals received from the
PCM over the CCD Bus.
The oil temperature is calculated on all 1996 MY 41TE transmissions with the TRS. The
temperature sensor is part of the TRS. On all 1989 - 95 MY (and early production 1996 NS,
non-TRS,1996 MY with code 74 present), the transmission oil temperature is calculated through a
heat transfer equation that uses engine coolant temperature, battery/ambient temperature and
extended time off (if known) at start up.
Transmission Shift Scheduling
Once the engine is started, the TCM updates the transmission oil temperature based on the
following to determine an estimated oil temperature during vehicle operation (if a calculated oil
temperature is being used):
- Torque converter slip speed
- Vehicle speed
- Engine coolant temperature
- Battery/ambient temperature
Vehicles with "calculated oil temperature" track oil temperature reasonably accurate during normal
operation. However, if a transmission oil cooler is added, a transmission is overfilled, a
transmission oil cooler becomes restricted or if a customer drives aggressively in low gear, the
calculated oil temperature will be inaccurate. Consequently, the shift schedule selected may be
inappropriate for the current conditions.
The key highlights of the various shift schedules are as follows:
Extreme Cold: Oil temperature at start up below -16° F.
- Goes to "Cold" schedule above - 12°F oil temperature
- Park, Reverse, Neutral and 2nd gear only (prevents shifting which may fail a clutch with frequent
shifts)
Cold: Oil temperature at start up above - 12 ° F and below 36°F
- Goes to "Warm" schedule above 40° F oil temperature
- Delayed 2-3 upshift (approximately 22 - 31 MPH)
- Delayed 3-4 upshift (45 - 53 MPH)
- Early 4-3 coastdown shift (approximately 30 MPH)
- Early 3-2 coastdown shift (approximately 17 MPH)
- High speed 4-2, 3-2, 2-1 kickdown shifts are prevented
- No EMCC
Warm: Oil temperature at start up above 36° F and below 80° F
- Goes to "Hot" schedule above 80°F oil temperature
- Normal operation (upshift, kick-downs and coast-downs)
- No EMCC
Hot: Oil temperature at start up above 80° F
- Goes to "Overheat" schedule above 240° F oil temperature (250° F for 96 and prior MY)
- Normal operation (upshifts, kick-downs and coast-downs)
- Full EMCC, no PEMCC except to engage FEMCC (Except at closed throttle at speeds above 70 83 MPH)
Overheat: 96 and prior MY - Oil temperature above 250° F or engine coolant above 230°F
- Goes to "Hot" below 240° F oil temperature or "Super Overheat" above 260° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH) Delayed 3-4 upshift (41 - 48 MPH) 3rd gear FEMCC from 30 48 MPH 3rd gear PEMCC from 27 - 31 MPH
97 MY - Oil temperature above 240° F or engine coolant temperature above 244° F
- Goes to "Hot" below 230° F oil temperature or "Super Overheat" above 240° F oil temperature
- Delayed 2-3 upshift (25 - 32 MPH)
- Delayed 3-4 upshift (41 - 48 MPH)
- 3rd gear FEMCC from 30 - 48 MPH
- 3rd gear PEMCC from 27 - 31 MPH
Super Overheat: 97 MY - Oil temperature above 240°F
- Goes back to "Overheat" below 240 ° F oil temperature
- All "Overheat" shift schedules features apply 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kickdown or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
96 and prior MY - Oil temperature above 260°F
- Goes back to "Overheat" below 260 ° F oil temperature
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5431
- All "Overheat" shift schedule features apply
- 2nd gear PEMCC above 22 MPH
- Above 22 MPH the torque converter will not unlock unless the throttle is closed (i.e. at 50 MPH a
4th FEMCC to 3rd FEMCC shift will be made during a part throttle kick-down or a 4th FEMCC to
2nd PEMCC shift will be made at wide open throttle) or if a wide open throttle 2nd PEMCC to 1
kickdown is made.
Causes for operation in the wrong temperature shift schedule:
Extreme Cold or Cold shift schedule at start up:
- Defective Engine Coolant Temperature Sensor (calculated oil temperature vehicles only)
- Defective Battery/Ambient Temperature Sensor (calculated oil temperature vehicles only)
- Defective PCM (calculated oil temperature vehicles only)
- Defective sensor circuit (TRS equipped only)
Overheat or Super Overheat shift schedule after extended operation:
- Operation in city traffic or stop-and-go traffic
- Engine idle speed too high - Stuck AIS motor
- Aggressive driving in low gear
- Trailer towing in OD gear position (use "3" position if frequent shifting occurs)
- Cooling system failure causing engine to operate over 230° F
- Engine coolant temperature stays low too long - If engine coolant temperature drops below 150°
F. the transmission will disengage EMCC. Extended operation with the EMCC disengaged will
cause the transmission to overheat.
- A defective brake switch will cause the EMCC to disengage. Extended operation with the EMCC
disengaged will cause the transmission to overheat.
- Transmission fluid overfilled (TRS equipped only)
- Transmission cooler or cooler lines restricted (TRS equipped only)
- Defective sensor circuit (TRS equipped only)
Engine Speed (Hard-Wired and CCD Broadcast)
The TCM uses both direct engine speed input from the Crankshaft Position Sensor or distributor,
as well as calculated engine speed input from the PCM over the CCD Bus. The direct input is
required to provide immediate information for use by the TCM control logic. The CCD engine speed
data is used by the TCM fail-safe logic to confirm that the direct engine speed data is valid.
MAP Sensor (CCD Broadcast)
The MAP Sensor provides engine load input directly to the PCM, which determines engine torque
load on the transaxle input shaft. These signals are broadcast over the CCD Bus to the TCM. The
TCM uses this information to modify shifting and reduce 2-3 and 3-4 shift hunting on grades.
Engine Idle Speed (Hard-Wired and CCD Broadcast)
The TCM uses direct engine idle speed input and calculated engine idle speed (or target idle
speed) input from the PCM over the CCD Bus. Target idle speed is compared against actual
engine speed to determine the learned Throttle Position Sensor (TPS) value for closed-throttle idle.
Brake Switch (CCD Broadcast)
The Brake Switch signal is a CCD broadcast message and is used to ensure that the torque
converter clutch is disengaged when the brakes are applied. It is used also to cancel cruise control
when the brakes are applied. The Brake Switch is hard-wired to the PCM and bussed to the TCM.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5432
Battery/Ambient Temperature Sensor (CCD Broadcast)
The battery temperature sensor is located in the Powertrain Control Module (PCM). This CCD
broadcast information is used to control charging system, engine and transaxle operation. The
TCM uses the battery temperature signal to estimate transaxle fluid temperature. When the TCM
detects lower temperatures, it adjusts the operation of the transaxle to allow for slower response of
the valves and fluid. If a failure of the Transmission Temperature Sensor occurs, the TCM uses the
Battery Temperature signal along with engine coolant temperature to calculate the temperature.
Shift Lever Position (SLP)
The TCM identifies the position of the manual lever by comparing the current switch positions of
the Transmission Range Sensor (TRS). This is accomplished by logic circuitry within the TCM. The
primary function of SLP logic is to provide safe, continuous, but limited operation of the transaxle
with the presence of an invalid or transition input code. The SLP logic function screens the input
codes from the switches and provides an SLP output signal to control actual gear selection.
Inputs include the codes indicated by the TRS current shift lever position, pressure switch
indications and speed ratio data from the input to most of the other functions in the TCM.
The identified position is stored in memory. The current switch position is determined by sensing
the voltage changes that occur at the corresponding TCM pin terminals for the switches. The TCM
receives the switch signal and processes the data. On vehicles with a BCM, the TCM sends the
Shift Lever Position information to the BCM and the cluster electronic PRNDL display via the CCD
Bus. The cluster electronic PRNDL display illuminates the appropriate shifter position indicator on
the instrument cluster. For vehicles without a BCM, the shifter position indicator is cable-operated.
CAUTION: An incorrect input (for example, a defective switch) of one of these positions could, with
sufficient time, result in either a pressure switch or speed check fault, when in fact the real cause is
a TRS fault. this type of fault can occur, for example, when the manual valve porting is in reverse
but the code is indicating "OD." In this case, the low/reverse pressure switch data and input speed
data will not agree with the expected results for shift lever position = "OD." Therefore, it is important
to perform a shift lever position test with the DRB scan tool before diagnosing any trouble codes.
It is extremely important that accurate shift lever position data be available to the TCM. The
accuracy of any diagnostic trouble code found in memory is doubtful unless the Shift Lever Test,
performed on the DRB Scan Tool, passes without fail.
Torque Management Signal (CCD Broadcast)
With some engines, the TCM sends a direct input, torque management request signal to: the PCM.
This occurs during high torque, high speed 1-2, 2-3, 4-2 and 3-1 shifts. The TCM torque
management request signal is used in order to reduce the torque applied in the 2-4 and OD
clutches. The PCM uses the TCM's torque management signal to shut off a certain number of fuel
injectors and to retard ignition timing slightly. This controls or reduces torque output of the engine
during certain shift sequences. The torque reduction is not detectable by the driver and lasts for a
very short time period. The PCM sends a confirmation of the request to the TCM over the CCD
Bus. If the confirmation signal is not received by the TCM, a diagnostic trouble code will eventually
be set.
The torque management signal is basically a 9-volt supply to the PCM. A torque management
request is recognized by the PCM when the TCM grounds the circuit. The circuit at the TCM is
called TRD link, which stands for "Torque Reduction Link."
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5433
PRNDL Switch (Hard-Wired)
NOTE: Used up to 1995 (Early 96 NS)
The PRNDL Switch is mounted to the case in the valve body area. The input from the switch along
with the Park/Neutral position switch tells the TCM what gear range was selected by the driver. The
TCM uses this input to determine what gear range and shift pattern to use.
Park/Neutral Position Switch (Hard-Wired)
NOTE: Used up to 1995 and early 96 NS
The Park/Neutral position switch operates the Starter Relay and both the Park/Neutral position and
Transmission Temperature Sensors operate the back-up lamp relay. The Park/Neutral Position
Switch does not allow starter engagement in any position other than Park "P" or Neutral "N." Both
switches must be closed to operate the back-up lamps.
Transmission Range Sensor (Hard-Wired)
The Transmission Range Sensor (TRS) replaces the P/N Position Switch and the Transmission
Range Switch that are found on vehicles prior to the 1996
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5434
MY. This sensor allows for accurate transaxle gear position identification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5435
Control Module: Description and Operation TCM Outputs
General Information
The TCM directly controls the following:
- Transmission Control Relay
- Solenoid pack
- Torque management requests to the PCM
Additionally, the TCM broadcasts the following information over the CCD Bus for use by other
vehicle control systems (Indirect Outputs):
- Communication with the DRB Scan Tool for diagnostics
- Shift lever position to the BCM
- Shift lever position to the shift lever display
- Transmission oil temperature to the PCM in order to activate the cooling fans
- Vehicle speed Hard-wired to PCM and PCM sends to BCM over CCD Bus
- Limp - in Status
- Transmission Temperature
- In-gear position
NOTE: MIL request is from the PCM.
Transmission Control Relay
The instant the ignition is turned "ON," the TCM performs a self-test to determine if its internal
electronic circuits are all working properly. If the self-test results are good, then the TCM sends
battery voltage to the Transmission Relay control circuit. The relay closes its internal contacts,
which then supply battery voltage to the TCM, the four solenoids and the three pressure switches
in the solenoid assembly. If the TCM "sees" a problem in the system, it turns off the power feed to
the Transmission Control Relay, causing the contacts to open. A diagnostic trouble code is then
stored in memory. The Transmission Control Relay is located in various places depending on the
vehicle model.
Solenoid and Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5436
When the Transmission Control Relay contact points are closed, the solenoid assembly receives
electrical power. The TCM can then operate the solenoids, as determined by its programming. The
relay provides power to all four solenoids through a single wire. This means that all the solenoids
have voltage supplied to them whenever the Transmission Control Relay is closed. The solenoids,
however, are not energized until the TCM grounds the solenoid return wire for the solenoid that is
needed.
The assembly is mounted to the outside of the transaxle case, under a sound shield protective
cover, toward the front of the vehicle. There are two gaskets that seal the solenoid pack to the steel
plate. There are also small solenoid valve filters used to protect the valves from contamination.
These filters are not replaceable. If the valve body and solenoid pack have been heavily
contaminated, the solenoid pack should be closely inspected to determine if it should be replaced.
The solenoid pack is not a serviceable unit.
The Solenoid and Pressure Switch Assembly is supplied voltage by the Transmission Control
Relay. The assembly consists of four solenoid/valve assemblies that control hydraulic pressure to
four of the five clutches in the transaxle and the torque converter clutch. A unique feature of the
solenoid/valves is that they directly control the application of a clutch. In other electronically
controlled transaxles/transmissions, the clutches are indirectly controlled by the solenoids through
normal hydraulic valving. The solenoid assembly also contains pressure switches that feed
information to the TCM.
Vehicle Speed Signal
The vehicle speed signal is sent as a direct input from the TCM to PCM. The output speed sensor
signal is sent to the.TCM and used as the vehicle speed signal. The TCM converts the output
speed sensor signal to an 8000 pulse-per-mile signal. The signal is then sent directly to the PCM.
The PCM receives this signal and converts it to a signal that can be used by the Body Control
Module (BCM), which controls the instrument cluster. The signal from the PCM to the BCM is sent
over the CCD Bus.
Overdrive Lockout (1994 - 95 AS, 1995 - 97 FJ)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5437
On AS and FJ vehicles, the 41TE four-speed overdrive automatic transaxle includes an overdrive
lockout function operated by a button on the instrument panel. The lockout feature makes driving
smoother in traffic at low and moderate speeds where overdrive is not needed. Otherwise, the
transaxle may shift in and out of overdrive, causing unnecessary shifting.
NOTE: The overdrive lockout switch on 1994 as vehicles is a momentary contact switch. No FJ
vehicles use a momentary contact switch.
Pushing the instrument panel button closes the switch. The TCM then locks out overdrive and
provides a ground to the O/D lockout lamp. Pushing the button again causes the TCM to return to
normal operation and turn off the overdrive lockout lamp.
With overdrive locked out, the transaxle upshifts to third gear in the same manner as in overdrive. If
the "3" position is selected on AS body vehicles, a high load is assumed and the part-throttle 2-3
upshift occurs at a higher speed to aid acceleration. If "3" is selected with overdrive locked out, an
earlier downshift to second gear occurs. Wide-open throttle shifts are unaffected by use of the
overdrive lockout switch or selection of the "3" position.
Electronic Pinion Factor
A pinion factor is stored in the TCM in order to provide the appropriate distance pulses for a
vehicle. The pinion factor is programmed into the TCM at the factory on new vehicles. If a TCM is
replaced, the electronic pinion factor must be programmed with the DRB Scan Tool.
The nature of the Electronic Pinion Factor requires that certain features must be taken into
consideration:
- If no pinion factor is stored in an installed TCM, the vehicle speedometer will not indicate speed
when moving
- Selecting the wrong final drive ratio or tire size may cause the speedometer accuracy to fall out of
specification
Use the following procedures to set the electronic pinion factor using the DRB Scan Tool:
- Select "Transmission" system, then -"Miscellaneous" functions, then "Pinion Factor". The DRB will
display the current tire size.
- If the tire size is incorrect, depress the Enter key and then select the correct size.
- Depress the Page Back key to exit the reset procedure.
Shifter/Ignition Interlock
The Shifter/Ignition Interlock is a mechanically cable operated system that interconnects the
automatic transmission floor mounted, or column, shifter to the steering column ignition switch. The
interlock system locks the floor mounted shift lever into the PARK position whenever the ignition
switch is in the LOCK or ACCESSORY position. When the key is in the OFF or RUN position, the
shifter is unlocked and will move into any position. The interlock system also prevents the ignition
switch from being turned to the LOCK or ACCESSORY position unless the shifter is in the PARK
position.
Shift Position Indicator
The shifter position indicator is located in the instrument cluster. The shifter position indicator
outlines with a box the gear position the transaxle manual valve lever is in.
The Transmission Range Sensor, or PRNDL/Park Neutral combination, sends a signal to the TCM
on the position of the transaxle manual valve lever. The TCM receives the switch signal and
processes the data. The TCM sends the Shift Lever Position (SLP) information to the BCM over the
CCD Bus. The BCM then outlines the appropriate shifter position indicator in the instrument cluster.
Autostick
Autostick is a driver-interactive transaxle feature that offers manual gear shifting capability. When
the shifter is moved into the Autostick position, the transaxle remains in whatever gear it was using
before Autostick was activated. Moving the shifter to the left (towards the driver) causes a
downshift, and moving it to the right (towards the passenger) causes an upshift. The instrument
cluster will illuminate the selected gear. The vehicle can be launched in 1st, 2nd or 3rd gear while
in the Autostick mode. Speed control will be deactivated if the transaxle is shifted to 2nd gear.
Shifting into OD position cancels the Autostick mode, and the transaxle resumes the OD shift
schedule.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Description and
Operation > General Information > Page 5438
Automatic Overrides
Some shifts are executed automatically or prevented Automatic shifts will occur under the
illustrated conditions:
Additionally, under certain circumstances, the TCM may take over and override the autostick
features, for example, under the following conditions:
- Autostick switch input errors
- Error overspeed
- Engine overheating
- Transmission overheating Autostick shifts are not permitted under the illustrated conditions:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information
Control Module: Service and Repair General Information
Do not interchange Transmission Control Modules with previous-year transmission control
modules. If a same year TCM is being used from a different vehicle, the following procedures must
be performed:
- Quick Learn Procedure
- Electronic Pinion Procedure
The Transmission Control Module is located on the right fender inner panel, in the engine
compartment. It is held in place by four mounting screws.
NOTE: If the Transmission Control Module has been replaced, the following procedures must be
performed:
- Quick Learn Procedure: This procedure will allow the transmission control module to learn the
characteristics of the vehicle.
- Electronic Pinion Factor Procedure: This procedure will reprogram the TCM to compensate for
different tire sizes and final drive ratios.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Control Module, A/T > Component Information > Service and
Repair > General Information > Page 5441
Control Module: Service and Repair Replacement
NOTE: For JA/JX with 2.4L engine, remove air cleaner clamps and air cleaner.
REMOVAL
1. Disconnect the battery negative cable.
2. Loosen 60 way retaining screw, located in the center of the 60 way connector. Then disconnect
the 60 way connector on Transmission Control
Module.
3. Remove Transmission Control Module mounting screws and lift module from vehicle.
INSTALLATION
To install, reverse removal procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations
Transmission Control System Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 5445
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Relays and Modules Transmission and Drivetrain > Relays and Modules - A/T > Transmission Control System Relay, A/T > Component
Information > Locations > Page 5446
Transmission Control Relay
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams
Transmission Range Sensor (TRS) Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5452
Transmission Mode Switch: Description and Operation
PARK/NEUTRAL POSITION SWITCH INPUT (ATX)
Circuit Operation On vehicles equipped with the ATX transmission, circuit T41 provides an input to
the Powertrain Control Module (PCM) on gearshift position.
Circuit T41 connects to cavity 76 of the PCM.
TRANSMISSION RANGE SENSOR (TRS)
The Transmission Range Sensor (TRS) is located internal to the transmission. This sensor
provides the Transmission Control Module (TCM) with information on shift lever position, contains
the transmission temperature sensor, and contains the switch for the back-up lamps.
Circuit Operation Circuit T1 provides an input to the TCM when the shift lever is in the
NEUTRAL/OVERDRIVE or LOW position.
Circuit T3 provides an input to the TCM when the shift lever is in the PARK, 3, or LOW position.
Circuit T42 provides an input to the TCM when the shift lever is in the PARK, REVERSE,
NEUTRAL, or LOW position.
Circuit T41 provides an input to the TCM when the shift lever is in the PARK, or NEUTRAL
position. This circuit is also the ground circuit for the coil side of the engine starter motor relay.
The TRS is case grounded to the transmission.
Power for the back-up lamp portion of the TRS is supplied by circuit F20. This circuit is HOT in the
RUN position only, and protected by a 10 amp fuse located in cavity 12 of the junction block.
When the operator places the vehicle in REVERSE circuits F20 and L1 are connected. The L1
circuit is connected to the back-up lamps, automatic day/night mirror and/or the All-Wheel Drive
(AWD) solenoids, if equipped.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5453
Transmission Mode Switch: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
12. Remove TRS retaining screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Mode Switch, A/T > Component Information >
Diagrams > Page 5454
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 5463
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 5464
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > Customer Interest: > 21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear
Engagement > Page 5465
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5471
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-04-99 > Feb > 99 > Transmission Range Sensor - Production Change > Page 5472
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5477
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5478
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Transmission Position Switch/Sensor: >
21-07-98 > Apr > 98 > A/T - 41TE/AE 42LE Delayed Gear Engagement > Page 5479
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change
Transmission Position Switch/Sensor: All Technical Service Bulletins Transmission Range Sensor Production Change
NUMBER: 21-04-99
GROUP: Transmission
DATE: Feb. 26, 1999
SUBJECT: Service And Parts Information On 1999 Running Changes To Transmission Range
Sensor (TRS)
OVERVIEW: This bulletin explains the changes that occurred to the TRS for the 1999 model year
and lists which parts are needed when service is required.
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - 1993 (AC) Dynasty/New
Yorker/New Yorker Salon 1990 - 1993 (AG) Daytona 1990 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance 1990 - 1991 (AQ) Chrysler
Maserati TC 1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New
Yorker Fifth Avenue 1993 - 1995 (ES) Chrysler Voyager (European Market) 1995 - 1999 (FJ)
Sebring/Avenger/Talon 1996 - 1999 (GS) Chrysler Voyager (European Market) 1995 - 1999 (JA)
Cirrus/Stratus/Breeze 1996 - 1999 (JX) Sebring Convertible 1993 - 1999 (LH)
Concorde/Intrepid/Vision/New Yorker/LHS/300M 1996 - 1999 (NS) Town &
Country/Caravan/Voyager 1997 - 1999 (PR) Prowler
NOTE:
THIS INFORMATION APPLIES TO VEHICLES EQUIPPED WITH A 41TE OR 42LE TRANSAXLE.
THE FOLLOWING TABLE LISTS THE BUILD DATE (BY MODEL) FOR THE TRANSAXLES THAT
INCLUDE THE NEW TRS.
DISCUSSION:
A new Transmission Range Sensor (TRS) was designed for 1999 Model Year transaxles.
The original plan was to include these transaxles in 1999 vehicles at the start of production, but
was actually implemented as a running change during the 1999 model year.
NOTE:
EARLY MODEL 1999 VEHICLES WERE BUILT WITH 1998 STYLE TRANSAXLES. A JUMPER
CONVERSION HARNESS WAS USED TO MATE THE 1999 VEHICLE HARNESS TO THE 1998
TRANSAXLE TRS. FOR JA MODELS, THE MAIN HARNESS CONNECTOR WAS CHANGED TO
DIRECTLY FIT THE 1998 TRS.
This running change can cause confusion due to the differences seen within the 1999 model year
or when replacing a transaxle on older vehicles (1998 or earlier) with a 1999 model transaxle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 5485
The above information will help technicians and parts personnel select the proper parts when
working with these different combinations.
NOTE:
THE EASIEST WAY TO DETERMINE WHICH COMPONENTS ARE REQUIRED IS BY LOOKING
AT THE TERMINAL STYLE OF THE TRS FOR THE TRANSAXLE YOU ARE WORKING ON.
CAUTION:
1998 AND 1999 TRS ARE NOT INTERCHANGEABLE. THERE IS A DIFFERENCE IN THEIR
SIZE (THROUGH CASE DIAMETER).
The following guidelines will help determine which components are required when making related
repairs:
1999 Vehicle Needs A TRS Or Valve Body Assembly
^ Inspect the TRS for terminal type.
^ If the TRS has PIN terminals, order a 1998 TRS or Valve Body assembly for service.
^ If the TRS has BLADE terminals, order a 1999 TRS or Valve Body assembly for service.
1999 Vehicle Needs A Transaxle
^ Regardless of original transaxle type (1998 or 1999) a 1999 transaxle should be ordered for a
1999 vehicle.
NOTE:
IF THE 1999 VEHICLE HAD A CARRYOVER 1998 TRANSAXLE, THE HARNESS JUMPER
MUST BE REMOVED SO THE VEHICLE HARNESS WILL CONNECT WITH THE 1999
TRANSAXLE TRS. JA MODELS DID NOT USE A HARNESS JUMPER AND A 1999 SPLICE KIT
WOULD BE REQUIRED.
1998 Or Earlier Vehicle Needs A TRS Or Valve Body Assembly
^ Order 1998 components for the transaxle.
1998 Or Earlier Vehicle Needs A Transaxle
^ If the applicable model year transaxle is ordered and received, no further action is required.
^ If a 1999 model transaxle is received for a 1998 or earlier vehicle, a TRS harness splice kit p/n
5014473AA 41TE or 5014474AA 42LE must be ordered to modify the vehicle harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Technical Service Bulletins > All Other Service Bulletins for Transmission Position Switch/Sensor: > 21-04-99
> Feb > 99 > Transmission Range Sensor - Production Change > Page 5486
NOTE:
THE SPLICE KIT WIRE COLORS MAY NOT MATCH THE WIRE COLORS ON THE VEHICLE
BEING WORKED ON. THE FUNCTIONALITY OF THE TRS TYPES IS THE SAME. THE SPLICE
KIT SHOULD BE INSTALLED WIRE FOR WIRE OR PIN FOR PIN AS THE ORIGINAL
CONNECTOR (FIGURE 1).
PARTS REQUIRED:
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly
Transmission Solenoid And Pressure Switch Assembly
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5489
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Transmission Solenoid and Pressure Switch Assembly > Page 5490
Transmission Position Switch/Sensor: Locations 4 Speed A/T
Automatic Transmission Electrical Connections (4 Speed)
Switch mounted in transaxle, (automatic only).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5491
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5492
Transmission Position Switch/Sensor: Description and Operation
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5493
Transmission Position Switch/Sensor: Service and Repair
NOTE: The transmission range sensor is located within the transaxle. To remove the TRS the
transaxle oil pan and valve body must be removed.
REMOVAL
1. Disconnect battery negative cable. 2. Remove engine air cleaner and tube.
3. Remove gearshift cable. 4. Remove manual valve lever. 5. Disconnect transmission range
sensor connector. 6. Hoist vehicle. 7. Carefully remove transaxle oil pan and drain fluid. 8. Remove
transaxle oil filter. Let transaxle oil drain fully. 9. Remove valve body retaining bolts.
10. Extract park rod from guide bracket and remove valve body from transaxle.
11. Place valve body on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Position Switch/Sensor, A/T > Component
Information > Locations > Page 5494
12. Remove TRS retaining screw.
13. Remove manual shaft seal.
14. Slide Transmission Range Sensor up the manual shaft and remove.
INSTALLATION
For installation, reverse removal procedure. Tighten TRS retaining screw to 5 Nm (45 inch lbs.).
Reseal transaxle oil pan using RTV.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control
Transmission Speed Sensor: Customer Interest Speed Sensor - Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-06-99 > Apr > 99 > Speed Sensor Intermittent Loss of Cruise Control > Page 5503
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 5508
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 5509
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Customer Interest for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T - 41TE/AE
42LE Delayed Gear Engagement > Page 5510
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control
Transmission Speed Sensor: All Technical Service Bulletins Speed Sensor - Intermittent Loss of
Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-06-99 > Apr > 99 >
Speed Sensor - Intermittent Loss of Cruise Control > Page 5516
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement
Technical Service Bulletin # 21-07-98 Date: 980424
A/T - 41TE/AE 42LE Delayed Gear Engagement
NO: 21-07-98
GROUP: Transmission
DATE: Apr. 24, 1998
SUBJECT: Delayed Transaxle Engagement
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 21-01-95 DATED FEB. 17,
1995 WHICH SHOULD BE REMOVED FROM YOUR FILES AND MARKED IN THE PERFECT
BOUND TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NUMBER 81-699-96084).
THE COMPLETE BULLETIN HAS BEEN REVISED.
MODELS
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (European Market)
1995 - 1998 (FJ) Sebring/Avenger/Talon
1996 - 1998 (GS) Chrysler Voyager (European Market)
1995 - 1998 (JA) Cirrus/Stratus/Breeze
1996 - 1998 (JX) Sebring Convertible
1993 - 1998 (LH) Concorde/Intrepid/LHS/New Yorker/Vision
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE OR 42LE TRANSAXLE.
POLICY: Information Only
Symptom/Condition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5521
Intermittent delayed transaxle engagement greater than three seconds. The transaxle may be cold
or hot based on the table as shown.
NOTE:
VEHICLES WITH DELAYED TRANSAXLE ENGAGEMENT ON START UP, AFTER BEING
PARKED FOR SEVERAL DAYS, ARE CONSIDERED NORMAL AND WILL NOT BE AFFECTED
BY THE INFORMATION IN THIS BULLETIN.
NOTE:
WHENEVER PERFORMING TRANSAXLE SERVICE, MAKE SURE THE TRANSMISSION
CONTROL MODULE (TCM) IS AT THE LATEST SOFTWARE LEVEL. USE THE FLASH
PROCEDURES TO UPDATE TRANSMISSION CONTROLLERS AS NECESSARY.
Diagnosis
Perform a transaxle fluid level check as described in the appropriate service manual. Perform Test
1 and Test 2 in the 41TE/AE - 42LE diagnostic manual (publication no. 81-699-97148 81-699-97031 or later). Make sure there are appropriate DRB III(R) communication and the SHIFT
LEVER SYSTEM TEST passes. After passing the above checks, use the table to help determine
the reason for delayed engagement.
NOTE:
TO USE THE TABLE EFFECTIVELY, MAKE SURE THE APPLICABLE SYMPTOMS/YEAR OF
VEHICLE AND DTC'S APPLY.
NOTE:
THE INFORMATION LISTED IN THIS TABLE DOES NOT ADDRESS ALL CONCEIVABLE
DELAYED ENGAGEMENT SCENARIOS. THIS INFORMATION DESCRIBES ISSUES OF
KNOWN IMPORTANCE THAT HAVE BEEN DIFFICULT TO DIAGNOSE AND REPAIR IN THE
FIELD.
Item 1 DTC 35 Loss of Prime
If multiple DTC's are seen with a 35, attempt to trace down alternate DTC's before addressing DTC
35. DTC 35 can only be set in a forward gear range. DTC 35 is very difficult to reproduce. If DTC
35 is seen with no other causes for loss of prime (low fluid level, poor filter installation etc.) the
pump will require replacement.
NOTE:
DURING A FLUID CHANGE PROCEDURE UNDER THE PROPER CONDITIONS DTC 35
COULD BE COULD BE GENERATED DUE TO NO/LOW FLUID LEVEL DURING THE
FILL/STARTUP PROCEDURE. IN THIS CASE, CODE 35 WOULD BE ERRONEOUS.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5522
Item 2 L - R Inner and Outer Seals
Leaking L - R inner and outer seals cause DTC 36 with a 50 or 51 along with initial symptoms of
stop bump for the vintage of vehicles listed in the table. Typically, the vehicle will be brought in for
the bump complaint. Stop bump will be the first symptom seen before experiencing delayed
engagements. When overhauling the transaxle, make certain to replace the L - R inner and outer
seals along with the piston retainer.
Background: The original L - R inner and outer seals were made from an AEM (Vamac) material
and were of a lip seal design. The AEM lip seals would take a compression set due to high
operating temperatures. The L - R seals were changed to an AEM D-ring design, but had the same
characteristics as the original seal. It was found that FKM (Viton) seals had better characteristics
than AEM. The L - R inner and outer seals were changed to an FKM D-seal. This L - R FKM D-seal
was implemented in transaxles with a build date of XXXX-2529-XXXX and greater. FKM D-seals
are currently being used and are the seals of choice.
Item 3 UD Inner Lip Seal
Leaking lip seals cause DTC 36 with a 51. This delay will be seen from N to OD (forward range
only). Additionally, this condition may cause launch shudder. When overhauling the transaxle,
make certain to replace the UD inner lip seal and replace the L - R inner and outer seals along with
the piston retainer.
Background: The original UD inner seal was made from AEM which had the same characteristics
as the original L - R seals. The UD seal retained the lip seal design but was changed to an FKM
material. The FKM UD lip seal was implemented in transaxles with a build date of
XXXX-1965-XXXX and greater. FKM UD lip seals are currently being used and are the seals of
choice.
NOTE:
THE L - R SEALS MUST BE CHANGED WITH THE UD SEAL. THE REASON IS THE L - R SEAL
WILL BE AEM AND MUST BE CHANGED TO FKM.
NOTE:
THE UD OUTER SEAL USED IN 1989 MODEL YEAR TRANSAXLES IS FATTER THAN THOSE
USED IN 1990 MODELS AND LATER. MAKE SURE THE PROPER SEAL IS SELECTED FROM
THE KIT FOR THE VINTAGE OF TRANSAXLE BEING WORKED ON.
Item 4 General Seal Statement
The seals within the transaxle are critical to its performance. Seals that have taken a set are not
able to seal properly. Inspect the lip of the lip seal to see if it is bent over and taken a set. Inspect
the D-ring's D-shape. It should be rounded and not flattened. After removing seals from their
location, place them back onto the component from which they were removed. Do they have slight
interference or do they sit loosely on the mating part? If they fit loosely, they have taken a set and
will require replacement.
In addition, seals that have taken a set can be detected using a pressure check during a cold start.
The L/R - U/D - and/or Rev pressures will be lazy once during the cold start. To duplicate the test,
the vehicle must sit until cold.
Always use the latest MOPAR seal kits to assure the latest seal technology. Depending on the year
of transaxle being worked on, replacing all seals to assure the latest seal composition is installed
throughout the transaxle is advisable. It is recommended to replace all clutch seals whenever a
transaxle recondition procedure is performed.
NOTE:
MANY AFTERMARKET SEAL KITS USE AEM SEAL RINGS. DO NOT USE AFTERMARKET
SEAL KITS SINCE THEY DO NOT INCLUDE FKM SEALS. USE MOPAR ORIGINAL EQUIPMENT
SEAL KITS WHENEVER REBUILDING A TRANSAXLE TO ENSURE THE LATEST SEAL
MATERIAL COMPOSITION.
Item 5 Measuring # 1 Check Ball Clearance
If the check ball does not have the appropriate amount of clearance, it may stick in the pocket
when the transaxle is hot.
NOTE:
THIS ONLY APPLIES TO EARLY MODEL YEAR (89-95) TRANSAXLES.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Transmission Speed Sensor: > 21-07-98 > Apr > 98 > A/T 41TE/AE 42LE Delayed Gear Engagement > Page 5523
Remove the valve body and use a dial caliper to check the distance between the top of the # 1
check ball and the top edge (machined surface) of the valve body (Figure 1). If the measurement is
less than 0.178 mm (.007 in.), replace the valve body with the most current part number for the
application.
Item 6 PRNDL Switch (Non TRS)
41TE transaxles with a PRNDL switch (non TRS) may exhibit a condition in freezing temperatures
where moisture collects in the switch and freezes. When this occurs the transaxle may have a
delay into reverse and generate DTC 24. This condition is temperature sensitive (intermittent) and
as the transaxle warms the condition will correct itself. The PRNDL switch will require replacement
to correct this condition.
Item 7 Output Speed Sensor
While vehicle is in park and engine idling, check the output speed sensor on the DRB III(R). If the
TCM indicates an output speed greater than zero RPM, the speed sensor, TRS, or thermistor may
be picking up electrical noise from the wiring harness or there is an intermittent ground problem. It
is important to note that the thermistor uses the same ground circuit as the speed sensor. Follow
wiring harness check described in DTC Tests 56, 57 and 58 to help with further diagnosis. Also,
see TSB 08-07-94 Rev. B.
Intermittent noise may cause reverse block logic to be activated. Look for output speed during a
park to reverse shift. If output speed noise exceeds 400 RPM, reverse block logic will be activated.
If the electrical noise is continuous, reverse block logic will exist until the condition is repaired. If the
condition is intermittent, or has been fixed, the output speed reading may be latched above 400
RPM. This will prevent a shift into reverse until the shifter is cycled to overdrive and back into
reverse.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 5524
Transmission Speed Sensor: Specifications
Input Speed Sensor .............................................................................................................................
...................................................... 27 Nm (20 ft. lbs.) Output Speed Sensor .....................................
........................................................................................................................................... 27 Nm (20
ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Technical Service Bulletins > Page 5525
Transmission Speed Sensor: Locations
Transmission Control Components
Input / Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input (Turbine) Speed Sensor Connector
Input Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Input (Turbine) Speed Sensor Connector > Page 5528
Output Speed Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Speed Sensor, A/T > Component Information >
Diagrams > Page 5529
Transmission Speed Sensor: Service and Repair
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Input (Turbine) Speed Sensor
INPUT
The input speed sensor is located to the left of the manual shift lever.
CAUTION: When disconnecting speed sensor connector, be sure that the weather seal does not
fall off or remain in old sensor.
Output Speed Sensor
OUTPUT
The output speed sensor is located to the right of the manual shift lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions
Transmission Temperature Sensor/Switch: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5535
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5536
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5537
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5538
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5539
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5540
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5541
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5542
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5543
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5544
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5545
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5546
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5547
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5548
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5549
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5550
Transmission Temperature Sensor/Switch: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5551
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5552
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Diagrams > Diagram Information and Instructions > Page 5553
Transmission Control System (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor
Transmission Temperature Sensor/Switch: Description and Operation Transmission Range Sensor
The transmission range sensor (on the valve body) sends a signal to the TCM on the position of
the transaxle manual valve lever. The TCM receives the switch signal and processes the data. The
TCM sends the Shift Lever Position (SLP) information to the BCM via the CCD bus. The BCM then
outlines with a box the appropriate shifter position indicator in the instrument cluster.
If a problem arises with the shifter position indicator, consult the following chart for diagnostic
information. If the malfunction cannot be corrected using the chart, consult the proper diagnostic
chart in Transmission Control Systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 5556
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Description and Operation
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 5557
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Transmission Range Sensor > Page 5558
Transmission Temperature Sensor/Switch: Description and Operation Transmission Temperature
Sensor - Circuit Operation
CIRCUIT OPERATION
The transmission temperature sensor is used to monitor the temperature of the transmission fluid.
The sensor is a variable resistor and is part of the Transmission Range Sensor (TRS).
Power for the sensor is supplied by the Transmission Control Module (TCM) on circuit T54. The
T54 circuit connects to cavity 54 of the TCM connector.
Ground for the sensor is supplied on circuit T13. This circuit is spliced with the turbine speed and
output speed sensor. This circuit connects to cavity 13 of the TCM connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Transmission and Drivetrain > Transmission Control Systems > Sensors and Switches Transmission and Drivetrain > Sensors and Switches - A/T > Transmission Temperature Sensor/Switch, A/T > Component
Information > Description and Operation > Page 5559
Transmission Temperature Sensor/Switch: Testing and Inspection
Chrysler does not provide a procedure to test the transmission temperature sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Light >
Component Information > Description and Operation
ABS Light: Description and Operation
The ABS system uses a yellow colored ABS Warning Lamp. The ABS warning lamp is located on
the right side of the message center located at the top of the instrument panel. The purpose of the
warning lamp is discussed in detail below.
The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition
which results in a shutdown of ABS function or when the body controller does not receive C2D
messages from the CAB. When the ignition key is turned to the on position, the ABS Warning
Lamp is on until the CAB completes its self tests and turns the lamp off (approximately 4 seconds
after the ignition switch is turned on). Under most conditions, when the ABS warning lamp is on,
only the ABS function of the brake system is affected. The standard brake system and the ability to
stop the car will not be affected when only the ABS warning lamp is on.
The ABS warning lamp is controlled by the CAB and the body controller through a diode located in
the wiring harness junction block. The junction block is located under the instrument panel to the
left of the steering column. The CAB and the body controller, controls the yellow ABS warning lamp
by directly grounding the circuit.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > ABS Main Relay >
Component Information > Description and Operation
ABS Main Relay: Description and Operation
ABS FUSES
Fuse Locations In Power Distribution Center
The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center
(PDC). The PDC is located on the drivers side of the engine compartment forward of the strut
tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the
junction block.
On vehicles equipped with traction control, the fuse for the traction control switch is also located in
the junction block.
The junction block is located on the left hand front cowl panel on the vehicle.
ABS RELAYS
On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are
located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will
need to be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid
Accumulator > Component Information > Description and Operation
Brake Fluid Accumulator: Description and Operation
HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER
There are two brake fluid accumulators in the Hydraulic Control Unit (HCU). There is one brake
fluid accumulator for the primary and secondary hydraulic circuits. The brake fluid accumulators
temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This
stored brake fluid is then used by the pump in the HCU to provide build pressure for the brake
hydraulic system.
Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a
mini brake fluid accumulator on the secondary hydraulic circuit which protects the master cylinder's
seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit.
On ABS equipped vehicles with traction control, in addition to the brake fluid accumulators there
are also two noise damping chambers in the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
> Component Information > Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Brake Fluid Pump
> Component Information > Diagrams > Page 5574
Brake Fluid Pump: Description and Operation
Integrated Control Unit (ICU)
The Hydraulic Control Unit (HCU) contains 2 pump assemblies, one for the primary and one for the
secondary hydraulic circuit of the brake system. Both pumps are driven by a common electric
motor which is part of the HCU. The pumps draw brake fluid from the fluid accumulators to supply
build pressure to the brakes during an ABS stop. The pump motor runs during the drive-off cycle as
a check and during an ABS stop and is controlled by the Controller Antilock Brake (CAB). The
Pump/Motor Assembly is not a serviceable item. If the pump/motor requires replacement the
complete HCU (minus the CAB) must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations
Diagnostic Connector - ABS: Locations
NOTE: The diagnostics of the ITT Teves Mark 20 ABS system is performed using the DRB scan
tool.
ABS BRAKE DIAGNOSTIC TOOL CONNECTOR
Diagnostic Scan Tool Data Link Connector
On this vehicle, the diagnostic connector used for the diagnosis of the ITT Teves Mark 20 ABS
system is located under the lower steering column cover, to the left side of the steering column, just
below the hood release lever. The ITT Teves Mark 20 ABS system uses the ISO 9141-K connector
which is shared by other vehicle diagnostic systems such as the powertrain control module and air
bag electronic control module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Diagnostic
Connector - ABS > Component Information > Locations > Page 5578
Diagnostic Connector - ABS: Description and Operation
NOTE: The diagnostics of the ITT Teves Mark 20 ABS system is performed using the DRB scan
tool.
ABS BRAKE DIAGNOSTIC TOOL CONNECTOR
Diagnostic Scan Tool Data Link Connector
On this vehicle, the diagnostic connector used for the diagnosis of the ITT Teves Mark 20 ABS
system is located under the lower steering column cover, to the left side of the steering column, just
below the hood release lever. The ITT Teves Mark 20 ABS system uses the ISO 9141-K connector
which is shared by other vehicle diagnostic systems such as the powertrain control module and air
bag electronic control module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
To HCU Mounting Bolts .......................................................................................................................
.................................................. 2 Nm (17 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 5582
Controller Antilock Brakes Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 5583
Controller Antilock Brakes Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Specifications > Page 5584
Electronic Brake Control Module: Description and Operation
The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds
and controls the antilock functions. The CAB contains two microprocessors that receive identical
sensor signals and then independently process the information. The results are then compared to
make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock
Brake System (ABS) amber warning lamp.
The primary functions of the CAB are to:
- detect wheel locking tendencies
- control fluid pressure modulation to the brakes during antilock stop
- monitor the system for proper operation
- provide communication to the DRB while in diagnostic mode
- store diagnostic information in non-volatile memory
The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is
detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its
hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system
with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic
circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor
during an antilock stop.
The antilock brake system is constantly monitored by the CAB for proper operation If the CAB
detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp.
If the antilock function is disabled, the system will revert to standard base brake system operation.
CAB Inputs Include The Following:
- ABS Warning Lamp
- Diagnostic Communication
- Four Wheel Speed Sensors
- Ignition Switch
- Fused B+
- Stop Lamp Switch
- Traction Control Switch
CAB Outputs Include The Following:
- ABS Warning Light Actuation
- Voltage
- Eight Valves
- Ten Valves With Traction Control
- Diagnostic Communication
- Body Controller Communication
- Traction Control Lamp Illumination
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Service and Repair > Removal
Electronic Brake Control Module: Service and Repair Removal
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control
Unit (HCU).
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
CAB 25 Way Connector
Unlocking CAB 25 Way Connector
4. Remove the 25 way connector from the Controller Antilock Brake (CAB) located on the bottom of
the HCU. The 25 way connector is removed
from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as
far out as possible. This will unlock and raise the 25 way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake
tubes.
5. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 5587
Brake Tube Connections To HCU
6. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
HCU To Suspension Cradle Mounting Bolts
7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.
8. Remove HCU and the mounting bracket as a unit from the vehicle.
HCU Mounting Bolts
9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the
mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 5588
Pump Motor To CAB Wiring Harness
10. Unplug the pump motor wiring harness from the CAB.
CAB Attaching Bolts
11. Remove the 4 bolts attaching the CAB to the valve block of the HCU.
Remove/Install CAB
12. Remove the CAB from the valve block of the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 5589
Electronic Brake Control Module: Service and Repair Installation
Remove/Install CAB
1. Install the Controller Antilock Brake (CAB) on the valve block of the Hydraulic Control Unit
(HCU).
CAB Attaching Bolts
2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting
bolts to a torque of 2 Nm (17 inch lbs.).
Pump Motor To CAB Wiring Harness
3. Plug the pump/motor wiring harness into the CAB.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 5590
HCU Mounting Bolts
4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting
bracket. Tighten the 3 mounting bolts to a torque
of 11 Nm (97 inch lbs.).
CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front
suspension crossmember.
HCU To Suspension Cradle Mounting Bolts
5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning valve, the brake tubes must be held in proper
orientation when tightened and torqued. These tubes must not contact each other or other vehicle
components when installed.
Brake Tube Connections To HCU
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Electronic Brake
Control Module > Component Information > Service and Repair > Removal > Page 5591
CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located
correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
HCU mounting bracket.
6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
Unlocking CAB 25 Way Connector
7. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
Brake Tube Routing Clips
8. Install the routing clips on the brake tubes. 9. Lower vehicle.
10. Connect negative cable back on negative post of the battery. 11. Bleed the base brakes and
the ABS brakes hydraulic system. 12. Road test vehicle to ensure proper operation of the base and
ABS brake systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Mounting Bracket To Suspension Cradle Bolts
.................................................................................................................................. 28 Nm (250 inch
lbs.) To Mounting Bracket Isolator Attaching Bolts
..................................................................................................................................... 11 Nm (97
inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Specifications > Page 5595
Hydraulic Control Assembly - Antilock Brakes: Locations
Teves Mark 20 ICU
Hydraulic Control Unit (Integrated) Mounting Location
Located behind the steering rack on the left side of the suspension crossmember.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Description and Operation > General Information
Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information
Teves Mark 20 ICU
The Hydraulic Control Unit (HCU) used with the Teves Mark 20 ABS is different from the HCU used
on previous Chrysler products with ABS. The HCU used on this ABS system is part of the
Integrated Control Unit (ICU). The HCU is part of what is referred to as the ICU because the HCU
and the Controller Antilock Brakes (CAB) are combined (integrated) into one unit. This differs from
previous Chrysler products with ABS, where the HCU and the CAB were separate components
located in different areas of the vehicle.
Teves Mark 20 ABS uses two different HCU's and CAB's depending on the type of ABS system the
vehicle is equipped with. There is a unique HCU and CAB for a vehicle equipped with just ABS and
a unique HCU and CAB for a vehicle equipped with ABS and traction control.
NOTE: The HCU and CAB used on a vehicle that is equipped with only ABS and on a vehicle that
is equipped with ABS and traction control are different. The HCU on a vehicle equipped with ABS
and traction control has a valve block housing that is approximately 1 inch longer on the low
pressure fluid accumulators side than a HCU for a vehicle that is equipped with only ABS.
ICU Mounting Location
The ICU is located on the driver's side of the vehicle, and is mounted to the front suspension
cradle. The ABS only ICU contains the following components for controlling the brake system
hydraulic pressure during ABS braking: The CAB, eight valve solenoids, (four inlet valves and four
outlet valves) fluid accumulators a pump, and an electric motor. The ABS with traction control ICU
contains the following components for controlling the brake system hydraulic pressure during ABS
braking and traction control operation: The CAB, four solenoid controlled inlet valves, four solenoid
controlled outlet valves, two hydraulic shuttle valves, two ASR valves, fluid accumulators a pump
and an electric motor. Also attached to the hydraulic control unit are the master cylinder primary
and secondary brake tubes and the brake tubes going to each wheel of the vehicle.
CAUTION: No components of the ICU are serviceable. If any component that makes up the ICU is
diagnosed as not functioning properly it MUST be replaced. The replaceable components of the
ICU, are the HCU and the CAB. The mounting bracket is also replaceable as a separate
component of the ICU. The remaining components of the ICU are not serviceable items. No
attempt should ever be made to remove or service any individual components of the HCU. This is
due to the concern of contamination entering the HCU while performing a service procedure. Also
no attempt should ever be made to remove or service any individual components of the CAB.
CAUTION: At no time when servicing the ICU should a 12 volt power source be applied to any
electrical connector of the HCU or the CAB.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 5598
Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Operation
General Information The Hydraulic Control Unit (HCU) contains the valve block assembly, two
accumulators, and pump/motor assembly. Located behind the steering rack on the left side of the
suspension crossmember.
Valve Block Assembly The valve block assembly contains valves with four inlet valves and four
outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are
spring loaded in the closed position. During and antilock stop, these valves are cycled to maintain
the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and
further pressure increase. Then the outlet valve is opened to release the pressure to the
accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet
valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within
its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant.
On JX and NS Bodies which are equipped with a traction control system, there are two additional
valves that isolate the master cylinder and rear wheels. During a traction control situation the
brakes are applied to reduce wheel slippage.
Pump/Motor Assembly The pump/motor assembly provides the extra amount of fluid needed during
antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet
valve is opened during and antilock stop. The pump is also used to drain the accumulator circuits
after the antilock stop is complete. The pump is operated by an integral electric motor. This
DC-type motor is controlled by the Control Antilock Brake (CAB). The CAB may turn on the pump
motor when an antilock stop is detected. The pump continues to run during the antilock stop and is
turned off after the stop is complete. Under some conditions, the pump/motor will run to drain the
accumulators during the next drive off. The pump mechanism consists of two opposing pistons
operated by an eccentric camshaft secondary hydraulic circuit. In operation, one piston craw fluid
from the accumulators. The opposing piston pumps fluid to the valve body solenoids. The CAB
monitors the pump/motor operation internally.
Accumulators The accumulators provide temporary fluid storage during an antilock stop and are
drained by the pump/motor. Each of the diagonal circuits uses a 5cc. accumulator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Description and Operation > General Information > Page 5599
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Valves and Solenoids
INLET VALVES AND SOLENOIDS
There are four inlet solenoids, one for each wheel. In the released position they provide a fluid path
from the master cylinder to the wheel brakes of the vehicle. When the ABS cycle has been
completed the inlet solenoids will return to their released (open) position.
OUTLET VALVES AND SOLENOIDS
There are four outlet solenoids, one for each wheel. In the released position they are closed to
allow for normal braking. In the actuated (open) position, they provide a fluid path from the wheel
brakes of the vehicle to the hydraulic control unit HCU accumulators and pump motor. The outlet
solenoids are spring loaded in the released (closed) position during normal braking.
ASR VALVE (ABS WITH TRACTION CONTROL ONLY)
On vehicles equipped with ABS having traction control, there are two special ASR valves located in
the HCU portion of the ICU. The ASR valves are a normally open type valve and are solenoid
actuated.
The special ASR valves are used to isolate the rear (non-driven) wheels of the vehicle from the
hydraulic pressure that the HCU pump motor is sending to the front (driven) wheels, when the
traction control system is in operation. The rear brakes need to be isolated from the master cylinder
when traction control is in operation so that the HCU can build the required hydraulic pressure to
the front brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Removal
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control
Unit (HCU).
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAB 25 Way Connector
4. Remove the routing clip attaching the HCU wiring harness to the HCU mounting bracket.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
Unlocked 25 Way CAB Connector
5. Remove the 25 way connector from the Controller Antilock Brake (CAB). The 25 way connector
is removed from the CAB using the following
procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will raise
and unlock the 25 way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake
tubes.
6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5602
Brake Tube Connections To HCU
7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
HCU To Suspension Cradle Mounting Bolts
8. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.
9. Remove HCU and the mounting bracket as a unit from the vehicle.
HCU Mounting Bolts
10. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the
mounting bracket. 11. Remove the CAB from the bottom of the HCU for installation on the
replacement HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5603
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Installation
CAB 25 Way Connector
1. Install the Controller Antilock Brake (CAB) on the bottom of the Hydraulic Control Unit (HCU).
HCU Mounting Bolts
2. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting
bracket. Tighten the 3 mounting bolts to a torque
of 11 Nm (97 inch lbs.).
CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front
suspension crossmember.
HCU To Suspension Cradle Mounting Bolts
3. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5604
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning valve, the brake tubes must be held in proper
orientation when tightened and torqued. These tubes must not contact each other or other vehicle
components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer
clips are reinstalled on the brake tubes.
Brake Tube Connections To HCU
CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located
correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
HCU mounting bracket.
4. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
Unlocked 25 Way CAB Connector
5. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to the HCU mounting bracket. This will ensure the
wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle.
6. Clip the cab wiring harness to the HCU mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Hydraulic Control
Assembly - Antilock Brakes > Component Information > Service and Repair > Removal > Page 5605
Brake Tube Routing Clips
7. Install the routing clips on the brake tubes. 8. Lower vehicle. 9. Connect negative cable back on
negative post of the battery.
10. Bleed the base brakes and the ABS brakes hydraulic system. 11. Road test vehicle to ensure
proper operation of the base and ABS systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Indicator Lamp > Component Information > Testing and Inspection
Traction Control Indicator Lamp: Testing and Inspection
The traction control light is tested by cycling the traction control switch on and off. The traction
control switch used on this vehicle is a momentary contact type switch. The test procedure for the
traction control light is performed as follows: Press the traction control switch once and the "Trac
Off" lamp will illuminate. With the "Trac Off" lamp illuminated, press the traction control switch again
and the "Trac Off" lamp will turn off.
If the traction control lamp does not function as described in the test above, diagnosis of the
traction control switch, lamp, wiring and other related components of the traction control system is
required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Harness Side
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Harness Side > Page 5613
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Page 5614
Traction Control Switch: Testing and Inspection
REMOVAL AND INSTALLATION
Traction Control Switch Connector
1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading
between pins. Refer to Switch Continuity Table.
Switch Continuity Table
Switch position - Continuity between Actuated - Pins 1 And 3 Illumination - Pins 2 And 3
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Traction Control
Switch > Component Information > Diagrams > Page 5615
Traction Control Switch: Service and Repair
Over Steering Column Bezel
REMOVAL
1. Remove the over steering column bezel. 2. Remove the two screws attaching traction control
switch to the bezel.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Resistance 900 - 1,300 ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Specifications > Electrical Specifications > Page 5620
Wheel Speed Sensor: Mechanical Specifications
Total Indicator Run Out Allowed 0.006 in
Front Air Gap 0.014 - 0.059 in
Rear Air Gap 0.020 - 0.054 in
To Axle Or Steering Knuckle Mounting Bolt 105 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 5623
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Front > Page 5626
Wheel Speed Sensor: Diagrams Rear
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Page 5627
Wheel Speed Sensor: Description and Operation
Front Wheel Speed Sensor
Rear Wheel Speed Sensor (FWD)
One Wheel Speed Sensor (WSS) is located at each front and rear wheel of the vehicle. The wheel
speed sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is
generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the
stationary magnetic wheel speed sensor. The CAB converts the AC signal generated at each
wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate
hydraulic pressure via the HCU to prevent the wheel(s) from locking.
The front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is
part of the driveshafts outboard constant velocity joint. The rear wheel speed sensor is mounted
through the rear axle, rear brake support plate and directly to the rear bearing. The rear tone wheel
on a front wheel drive vehicle is an integral part of the rear wheel hub/bearing assembly. If
damaged though, the rear tone wheel on a front wheel drive vehicle can be replaced as a individual
component of the rear hub/bearing assembly. The wheel speed sensor air gap is NOT adjustable.
The rear tone wheel on a all wheel drive vehicle, is part of the outboard constant velocity joint on
the rear driveshaft.
The four wheel speed sensors are all serviced individually, but the front tone wheel on all vehicles
and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear
driveshaft outboard constant velocity joint.
Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's
wheels and tires must all be the same size and type to generate accurate signals. Variations in
wheel and tire size can produce inaccurate wheel speed signals, which can cause false ABS cycles
to occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Diagrams > Page 5628
Wheel Speed Sensor: Testing and Inspection
CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake
System are different then those used on past models of this vehicle equipped with antilock brakes.
Reduced braking performance will result if this part is used on earlier model vehicles and an
accident could result. Do not use on pre-1998 model year vehicles.
Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or
broken teeth, this can cause erratic speed sensor signals.
Tonewheels should show no evidence of' contact with the wheel speed sensors. If contact was
made, determine cause and correct before replacing the wheel speed sensor.
Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Replace drive
shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification.
Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their
mounting surfaces and should not rotate independently from the mounting surface.
Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the
speed sensor head and the tone wheel to ensure it is at specification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
Front Speed Sensor Cable Channel Bracket
3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame
rail.
CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not
to damage pins on connector
Speed Sensor Cable To Vehicle Wiring Harness
4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect
speed sensor cable from vehicle wiring harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5631
Front Wheel Speed Sensor Attaching Bolt
5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor
head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON
SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free.
Front Wheel Speed Sensor Cable Routing
7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front
wheel speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in
this section may result in contact with moving parts and/or over extension of cables, resulting in an
open circuit.
1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure
speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut
tower.
CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the
channel bracket.
2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching
the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4.
Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to
steering knuckle on the rearward side of the
stabilizer bar link.
5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor
attaching bolt to a torque of 12 Nm (105 inch lbs.). 6. Check the air gap between the face of the
wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Rear
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to
damage pins on the electrical connectors. Also inspect connectors for any signs of previous
damage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5632
Rear Speed Sensor Cable Connection To Vehicle Wiring Harness
3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from
vehicle wiring harness.
CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during removal of the speed sensor cable.
Speed Sensor Cable Attachment To Brake Flex Hose
4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips.
Right Rear Speed Sensor Cable Routing
5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the
axle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5633
Rear Speed Sensor Routing Brackets And Clips
6. Remove the 2 rear wheel speed sensor cable/ brake tube routing clips. Then un-clip the speed
sensor cable from the routing clips on rear brake
tube.
CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor
head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the
sensor from side to side until free.
Rear Wheel Speed Sensor Attaching Bolt
7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not
come loose, do not use pliers. Tap with screw driver
and hammer.
8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed
sensor assembly from vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in
this section may result in contact with moving parts and/or over extension of cables, resulting in an
open circuit.
1. Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must
be fully seated into the bearing flange.
2. Install the wheel speed sensor head to bearing Range attaching bolt. Tighten the attaching bolt
to a torque 12 Nm (105 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor
and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle.
The rear wheel speed sensor cable should be routed
under the rear brake tube.
CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during installation of the wheel speed
sensor cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5634
5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear
speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket.
CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed
sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the
vehicle wiring harness, do not force the connectors together. If the connectors are forced together,
damage to the connectors will occur.
7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable
connector is fully seated and locked into vehicle wiring
harness connector.
8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into
the body hole. 9. Install the tire and wheel assembly on vehicle.
10. Road test vehicle to ensure proper operation of the base and ABS braking systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5635
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and
tire assembly. 3. Remove rear brake drum from the hub/bearing assembly.
Rear Wheel Speed Sensor
4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing assembly.
Rear Hub/Bearing Mounting Bolts
5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle.
Removing Rear Hub/Bearing From Axle
6. Remove the hub/bearing assembly from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5636
Tone Wheel Removal From Hub/Bearing Assembly
7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage
by the vise jaws. Mount the hub/bearing assembly
in a vise. Using Puller, Special Tool C-4693 or equivalent installed as shown remove the tone
wheel from the hub/bearing assembly.
INSTALL
Installing Tone Wheel On Hub/Bearing Assembly
1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3 or
equivalent. Position Driver, Special Tool 6908-1
or equivalent with undercut side facing up on top of the tone wheel.
Correctly Installed Tone Wheel
2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3.
Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the
rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the
rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts
into hub/ bearing assembly. Tighten the 4 bolts in a
criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto
flange of rear axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Antilock Brakes / Traction Control Systems > Wheel Speed
Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 5637
6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 7. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
8. Check the air gap between the face of the wheel speed sensor and the top surface of the
tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
9. Install the brake drum onto the rear hub/bearing assembly.
10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust
the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Base Brake System Bleeding Procedures
Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures
Bleeding Base Brake Hydraulic System
NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For
bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake
System bleeding procedure in antilock brakes.
Pressure Bleeding Procedure
CAUTION:
- Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid
reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid
reservoir.
- Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
- When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be
removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid
reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system
is pressurized.
Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment.
Air Trapped In Brake System
When bleeding the brake system, some air may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow
of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.
1. Remove the filler neck from the master cylinder fluid reservoir.
Pressure Bleeding Cap Installed On Master Cylinder
2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the
fluid reservoir of the master cylinder. Attach the
fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent.
3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar
containing fresh brake fluid.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Base Brake System Bleeding Procedures > Page 5642
adequate removal of all trapped air from the brake hydraulic system.
(1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel
Rear Wheel Cylinder Bleeder Screw
4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow
of brake fluid.
CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid
discharge will NOT get all the air out.
5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free
flow is maintained in the hose and jar, this will
indicate a good bleed of the hydraulic system has been obtained.
6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been
improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to
monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the
brake system through the master cylinder.
7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Bleeding Without A Pressure Bleeder
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must
be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are
correctly adjusted.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure adequate removal of all trapped air from the brake
hydraulic system.
- Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed.
4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence.
This should pass a sufficient amount of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Bleeding > System Information > Service and Repair >
Base Brake System Bleeding Procedures > Page 5643
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
Bleeding Teves Mark 20 Hydraulic System
The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to
disconnection of brake lines, hoses or components. The ABS system, particularly the HCU, should
only be bled when the HCU is replaced or it is removed from the vehicle, or if there is reason to
believe the HCU has ingested air. Under most circumstances that would require brake bleeding,
only the base brake hydraulic system needs to be bled.
It is important to note that excessive air in the brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level
in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding
procedure and add DOT 3 brake fluid as required.
The ITT Teves Mark 20 ABS must be bled as two independent braking systems. The non ABS
portion of the brake system is to be bled the same as any non ABS system. This brake system can
be either pressure bled or manually bled.
The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires
the use of the DRB Diagnostic Tester and the bleeding sequence procedure outlined below.
ABS BLEEDING PROCEDURE
When bleeding the ABS system, the following bleeding sequence MUST be followed to insure
complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure
or standard pressure bleeding equipment.
If the brake system is to be bled using pressurized bleeding equipment, refer to Bleeding Base
Brakes. 1. Assemble and install all brake system components on the vehicle making sure all
hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to
the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the
instrument panel to the left of the steering column cover.
3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault
codes stored. If it does, remove them using
the DRB.
WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube must be
attached to the bleeder screws and submerged in a clear container filled part way with clean brake
fluid. Direct the flow of brake fluid away from the painted surfaces of the vehicle. Brake fluid at high
pressure may come out of the bleeder screws when opened.
4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5.
Using the DRB, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed
ABS" cycle one time. Release the brake
pedal.
6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6
above until brake fluid flows clear and is free of any air bubbles. Check brake fluid level in reservoir
periodically to prevent reservoir from running low on brake fluid.
8. Test drive the vehicle to be sure brakes are operating correctly and that the brake pedal does
not feel spongy.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Pedal Assy > Component Information > Specifications
Brake Pedal Assy: Specifications
Pedal Ratio ..........................................................................................................................................
............................................................................ 3.36
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test
Revisions
NUMBER: 26-12-97I
GROUP: Miscellaneous
DATE: December, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013
DESCRIPTION OF CHANGES
Revisions to the ABS warning lamp test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5651
94
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5652
95
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5653
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS
Revisions
NUMBER: 26-12-97F
GROUP: Miscellaneous
DATE: December, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012
DESCRIPTION OF CHANGES
Revisions to the ABS warning light procedure
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5654
244
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 5655
245
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Brake Warning Indicator > Component Information > Technical
Service Bulletins > Page 5656
Brake Warning Indicator: Description and Operation
The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low
brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank
position.
The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit either through the park brake switch, the fluid
level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the crank
position.
The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly.
The purpose of the sensor is to provide the driver with an early warning that brake fluid level in the
master cylinder fluid reservoir has dropped to below normal. This may indicate: (1) Abnormal loss
of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. (2)
Brake shoe linings which have worn to a point requiring replacement.
As the brake fluid drops below the minimum level, the brake fluid level sensor closes to ground the
brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder
fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid
level has dropped below the add line in the master cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evidence of a leak.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 5666
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 5667
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 5668
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 5669
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes - Howl/Moan From The
Rear > Page 5670
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5676
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5677
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5678
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5679
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5680
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Page 5681
Brake Caliper: Specifications
Bore Diameter 60 mm
Caliper Mounting Bolts 16 ft.lb
Guide Pin Bolts 30 ft.lb
Bleeder Screw 125 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Technical Service Bulletins > Page 5682
Brake Caliper: Testing and Inspection
CLEANING AND INSPECTION
Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any
ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak
is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if
scored.
Check the guide pin dust boots to determine if they are in good condition. Replace if they are
damaged, dry, or found to be brittle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
Front
CAUTION: During service procedures, grease or any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing
assembly.
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove the 2 caliper to steering knuckle guide pin bolts.
Caliper Assembly Mounting On Steering Knuckle (Typical)
4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5685
Storing Front Disc Brake Caliper
5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex
hose. Supporting weight of caliper by the brake
fluid flex hose, can damage the flexible brake hose.
INSTALL
1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose
Lubricant, or equivalent.
CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals
on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.
2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper
end of caliper over the machined abutment on
steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that
caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
3. Install the caliper guide pin bolts and tighten to a torque of 55 Nm (40 ft. lbs.). Extreme caution
should be taken not to cross thread the caliper
guide pin bolts.
4. Install the wheel and tire assembly 5. Using a torque wrench, tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to half specification. Then repeat the
tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake pedal.
Rear
GENERAL INFORMATION
During service procedures, grease or any other foreign material must be kept off brake shoe
assemblies, and braking surfaces of rotor.
Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and
scratching or nicking of lining on the brake shoes.
If inspection reveals that the caliper piston seal is leaking, it MUST be replaced immediately.
During removal and installation of a wheel and tire assembly, use care not to strike the caliper.
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies
from vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5686
Removing Caliper Guide Pin Bolts
3. Remove the disc brake caliper to adapter guide pin bolts.
Removing/Installing Caliper
4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Correctly Supported Caliper
5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose.
INSTALL
NOTE: Step 1 below is only required when installing the disc brake caliper after new brake shoes
have been installed.
1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both
adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5687
3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the
hub.
CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting bosses.
4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse
procedure for removal.
CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the
caliper guide pin bolts.
5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.).
6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
8. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop vehicle.
9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and
to seat the brake shoe linings.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5688
Brake Caliper: Service and Repair Disassembly and Assembly
Disassembly and Assembly
DISASSEMBLY
WARNING: Under no condition should air pressure ever be used to remove a piston from a caliper
bore. Personal injury could result from such a practice.
1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic
fluid cannot get on rotor. Place a small piece of
wood between the piston and caliper fingers.
2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold
down the brake pedal to any position beyond the First
inch of pedal travel. This will prevent loss of brake fluid from the master cylinder.
3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at
frame rail. Plug brake tube and remove piston fram
opposite caliper using the same process as above for the first piston removal.
4. Disconnect the brake fluid flex hose from the caliper assembly.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin
sleeves and guide pin bushings.
Fig. 10 Dust Boot Removal
7. Remove the piston dust boot from the caliper and discard.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5689
Removing Piston Seal From Caliper
8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston
bore. Discard old seal. Do not use a screw driver
or other metal tool for this operation, because of the possibility of scratching piston bore or burring
edges of seal groove.
9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint
residue can remain in caliper bore. Clean out all
drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must
be installed at assembly.
Honing Brake Caliper Piston Bore
10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can
usually be cleared of the light scratches or corrosion
using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone,
Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than
0.0254 mm (0.001 inch).
11. If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or
scored.
NOTE: When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake
fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary
brush.
NOTE: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing
the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston
surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced.
12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is
evidence of scratches, pitting or physical damage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5690
ASSEMBLY
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
1. Clamp caliper in a vise (with protective caps installed on jaws of vise).
Installing New Piston Seal In Caliper
2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD
PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled.
3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position
dust boot over piston after coating with brake fluid.
CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston
in the bore of the caliper.
Installing Piston Into Caliper Bore
5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6.
Position dust boot into the counterbore of the caliper assembly piston bore.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5691
7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special
Tool C-4171 or equivalents, drive boot into
counterbore of the caliper.
8. Install guide pin sleeves and bushings. 9. Install brake pads.
10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described
in Checking Brake Rotor for Runout and
Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any
servicing, install caliper assembly.
11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly
banjo bolt to 33 Nm (24 ft. lbs.). New seal washers
MUST always be used when installing brake hose to caliper.
12. Bleed the brake system.
Guide Pin Bushing Service
NOTE: The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this
assembly can be serviced using the following procedure.
REMOVING CALIPER GUIDE PIN BUSHINGS
1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake
rotor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5692
Removing Inner Sleeve From Bushing
2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as
shown.
Removing Bushing From Caliper
3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove
the bushing from the brake caliper housing.
INSTALLING CALIPER GUIDE PIN BUSHINGS
Folded Caliper Guide Pin Bushing
1. Fold the bushing in half lengthwise at the solid middle section of the bushing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5693
Installing Caliper Guide Pin Bushing
2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step
due to possible damage to the bushing.
Bushing Correctly Installed In Caliper
3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the
caliper housing. Flanges should be seated evenly
on both sides of the bushing hole.
4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an
equivalent.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5694
Fig 7 Installing Caliper Sleeves
5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in
sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing
through boot until one end of bushing is fully seated into seal
groove on one end of sleeve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Caliper > Component Information >
Service and Repair > Removal and Installation > Page 5695
Fig 8 Installed Caliper Bushing Sleeve
7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on
sleeve. Be sure other end of bushing did not come
out of seal grove in sleeve.
8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be
held between your fingers and easily slid back and
forth without the bushing unseating from the sleeve groove.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Front
Brake Pad: Specifications Front
Brake Shoe Thickness Measurement
The combined brake shoe and lining material thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total thickness of approximately 7.95 mm (5/16 inch) or
less, they should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Specifications > Front > Page 5700
Brake Pad: Specifications Rear
Brake Shoe Thickness Measurement
The combined brake shoe and lining material thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch), they
should be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Cleaning and Inspection
Brake Pad: Service and Repair Cleaning and Inspection
FRONT
If a visual inspection does not adequately determine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the
calipers.
Remove the shoe and lining assemblies.
Combined shoe and lining thickness should be measured at the thinnest part of the brake shoe
assembly.
When a shoe and lining assembly is worn to a thickness of approximately 7.95 mm (0.313 inch) it
should be replaced.
Replace both shoe assemblies (inboard and outboard) on the front wheels. It is also necessary that
both front wheel brake shoe assembly sets be replaced, whenever shoe assemblies on either side
of the vehicle require replacement.
If a shoe assembly does not require replacement, reinstall it, making sure each shoe assembly is
returned to its original position.
REAR
If a visual inspection does not adequately determine the condition of the lining, a physical check will
be necessary. To check the amount of lining wear, remove the wheel and tire assemblies, and the
calipers.
Remove the rear disc brake shoes.
The combined brake shoe and lining material thickness should be measured at the thinnest part of
the assembly.
When a set of brake shoes are worn to a total thickness of approximately 7.0 mm (9/32 inch) they
should be replaced.
Replace both brake shoe assemblies (inboard and outboard). It is necessary that both rear wheel
sets be replaced whenever brake shoe assemblies on either side are replaced.
If the brake shoe assemblies do not require replacement, reinstall, the assemblies making sure
each brake shoe is returned to the original position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Cleaning and Inspection > Page 5703
Brake Pad: Service and Repair Front
REMOVE
WARNING: Although factory installed brake linings are made from asbestos free materials, some
after market brake lining may contain asbestos. This should be taken into account when servicing a
vehicle's brake system, when aftermarket brake linings may have been installed on the vehicle.
Always wear a respirator when cleaning brake components as asbestos can cause serious bodily
harm such as asbestosis and or cancer. Never clean brake components by using compressed air,
use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner
is not available, clean brake parts using only water-dampened shop towels. Do not create brake
lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected
of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended
safety practices prescribed by the Occupational Safety And Health Administration (OSHA) and the
Environmental Protection Agency (EPA), for handling and disposal of products containing
asbestos.
CAUTION: During service procedures, grease or any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing
assembly.
Removing Outboard Brake Pad From Caliper
1. Remove outboard brake pad, by prying the pad retaining clip over raised area on caliper. Then
slide the pad down and off the caliper.
Removing Inboard Brake Pad From Piston
2. Pull inboard brake pad away from piston, until retaining clip on brake pad is free from cavity in
caliper piston.
INSTALL
1. Completely retract caliper piston back into piston bore of caliper assembly. This is required for
caliper installation with new brake pad assemblies. 2. Remove the protective paper from the noise
suppression gasket on both the inner and outer brake pad assemblies (if equipped).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Cleaning and Inspection > Page 5704
Front Brake Shoe Assembly Identification
NOTE: The inboard and outboard brake pads are not common, refer to image for inboard and
outboard brake pad assembly identification.
Inboard Brake Shoe
3. Install the new inboard brake pad assembly into the caliper piston by firmly pressing into piston
bore. Be sure inboard brake pad assembly is
positioned squarely against face of caliper piston.
Installing Outboard Brake Shoe
4. Slide the new outboard brake pad assembly onto the caliper assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Cleaning and Inspection > Page 5705
Brake Pad: Service and Repair Rear
WARNING: Although factory installed brake linings are made from asbestos free materials, some
after market brake lining may contain asbestos. This should be taken into account when servicing a
vehicle's brake system, when aftermarket brake linings may have been installed on the vehicle.
Always wear a respirator when cleaning brake components as asbestos can cause serious bodily
harm such as asbestosis and or cancer. Never clean brake components by using compressed air,
use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner
is not available, clean brake parts using only water-dampened shop towels. Do not create brake
lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected
of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended
safety practices prescribed by the Occupational Safety And Health Administration (OSHA) and the
Environmental Protection Agency (EPA), for handling and disposal of products containing
asbestos.
GENERAL INFORMATION
During service procedures, grease or any other foreign material must be kept off brake shoe
assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing assembly.
Handling of the braking disc and caliper is to be done in such a way as to avoid deformation of the
disc and scratching or nicking of brake linings.
If inspection reveals that the square sectioned caliper piston seal is worn or damaged, it MUST be
replaced immediately.
During removal and installation of a wheel and tire assembly, use care not to strike the caliper.
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies
from vehicle.
Removing Caliper Guide Pin Bolts
3. Remove the caliper to adapter guide pin bolts.
Removing/Installing Caliper
4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Cleaning and Inspection > Page 5706
Correctly Supported Caliper
5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 6.
Remove the rear rotor from the hub by pulling it straight off the wheel mounting studs. 7. Remove
the outboard brake shoe from the caliper. Brake shoe is removed by prying brake shoe retaining
clip over raised area on caliper and
sliding the brake shoe off the caliper.
Removing Inboard Brake Pad From Piston
8. Remove inboard brake shoe from caliper. Inboard brake shoe is removed by pulling it out of the
caliper piston, until the retaining clip is free of the
piston.
CALIPER INSPECTION
Check for piston seal leaks (brake fluid in and around boot area and inboard lining) and for any
ruptures of the piston dust boot. If boot is damaged, or fluid leak is visible, disassemble caliper
assembly and install a new seal and boot, (and piston if scored).
Check the caliper dust boot and caliper pin bushings to determine if they are in good condition.
Replace if they are damaged, dry, or found to be brittle.
INSTALL
NOTE: Step 1 below is only required when installing a caliper after new brake shoes have been
installed.
1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both
adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent. 3. If
removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the hub.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Pad > Component Information >
Service and Repair > Cleaning and Inspection > Page 5707
Inboard Brake Shoe
4. Install the inboard brake shoe into the caliper piston by firmly pressing it into the piston bore
using your thumbs. Be sure inboard brake shoe is
positioned squarely against the face of the caliper piston.
5. Install the outboard brake shoe on the disc brake caliper
CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting bosses.
6. Carefully lower caliper and brake shoes over rotor and onto adapter, reversing the removal
procedure
CAUTION: When installing the caliper guide pin bolts extreme caution should be taken not to
cross-thread the guide pin bolts.
7. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.).
8. Install the wheel and tire assembly. 9. Tighten the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
10. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop the vehicle.
11. Road test the vehicle and make several stops to wear off any foreign material on the brakes
and to seat the brake shoe linings.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications
Brake Rotor/Disc: Specifications Brake Rotor Specifications
Brake Rotor Specifications
BRAKE ROTOR Front Rear
BRAKE ROTOR TYPE Ventilated Solid
BRAKE ROTOR DIAMETER (14"/15" Standard) 260 mm (10.24 in.) 381 mm (15.0 in.)
BRAKE ROTOR DIAMETER (15" Heavy Duty) 283 mm (117.92 in.) ----ROTOR THICKNESS 23.87 - 24.13 mm (0.939 - 0.949 in.) 12.25 - 12.75 mm (0.482 - 0.502 in.)
MINIMUM ROTOR THICKNESS 22.4 mm (0.881 in.) 11.25 mm (0.443 in.)
Minimum allowable thickness markings are cast/stamped on an
un-machined outer surface of the rotor. These thickness
markings include 0.76 mm (0.030 in.) allowable rotor wear
beyond the recommended 0.76 mm (0.030 in.) of rotor
refacing.
ROTOR THICKNESS VARIATION 0.013 mm (0.0005 in.) 0.013 mm (0.0005 in.)
ROTOR RUNOUT * 0.08 mm (0.003 in.) 0.08 mm (0.003 in.)
* TIR - Total Indicator Reading (measured on vehicle)
ROTOR MICRO-FINISH 15 - 80 RMS 15 - 80 RMS
Front Rotor Thickness Markings
Rear Rotor Thickness Markings
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 5711
Brake Rotor/Disc: Testing and Inspection
GENERAL INFORMATION
Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to
ensure proper brake action.
Before refinishing or refacing a rotor, the rotor should be checked and inspected for the following
conditions:
Braking surface scoring, rust, impregnation of lining material and worn ridges.
Excessive rotor lateral runout or wobble.
Thickness variation in braking surface of the rotor (Parallelism).
Dishing or distortion in braking surface of the rotor (Flatness).
If a vehicle has not been driven for a period of time, the rotors will rust in the area not covered by
the brake lining and cause noise and chatter when the brakes are applied.
Excessive wear and scoring of the rotor can cause temporary improper lining contact if ridges are
not removed from braking surface of rotor before installation of new brake shoe assemblies.
Some discoloration and/or wear of the rotor surface is normal and does not require resurfacing
when linings are replaced.
Excessive runout or wobble in a rotor can increase pedal travel due to piston knock-back. This will
also increase guide pin bushing wear due to the tendency of the caliper to follow rotor wobble.
Thickness variation in a rotor can also result in pedal pulsation, chatter and surge due to variation
in brake output. This can also be caused by excessive runout in the rotor and/or the hub.
Dishing or distortion can be caused by extreme heat and abuse of the brakes.
CHECKING ROTOR FOR RUNOUT AND THICKNESS
NOTE: The procedure for checking rotor runout and thickness is the same for the front and rear
rotor. If there is a specification difference between the front and rear rotor it will be designated as
such in the specifications of the following procedure.
Checking Brake Rotor For Runout
On-vehicle rotor runout is the combination of the individual runout of the hub face and the runout of
the rotor. (The hub and rotor run-outs are separable). To measure runout on the vehicle, remove
the wheel and reinstall the lug nuts tightening the rotor to the hub. Mount Dial Indicator, Special
Tool C-3339 with Mounting Adaptor, Special Tool SP-1910 or equivalent on steering arm. Dial
indicator plunger should contact braking surface of rotor approximately 10 mm (0.393 inch) from
outer edge of rotor. Check lateral runout on both sides of rotor. Lateral runout of the rotor should
not exceed 0.13 mm (0.005 inch).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 5712
Marking Rotor And Wheel Stud
If lateral runout is in excess of the specification, check the lateral runout of the hub face. Before
removing rotor from hub, make a chalk mark across both the rotor and one wheel stud on the high
side of the runout. This will ensure that the original location of the rotor in relation to the hub can be
retained. Remove rotor from hub.
Checking Disc Brake Rotor For Runout
Thoroughly clean the front surface of the front hub. Then install Dial Indicator, Special Tool C-3339
and Mounting Adaptor, Special Tool SP-1910 or equivalent on steering knuckle. Position stem so it
contacts hub face near outer diameter. Care must be taken to position stem outside the stud circle
but inside the chamfer on the hub face. Clean hub surface before checking.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 5713
Indexing Rotor And Wheel Stud
Lateral runout should not exceed 0.08 mm (0.003 inch). If runout exceeds this specification, the
hub must be replaced. See Steering and Suspension. If lateral runout of the hub does not exceed
this specification, install rotor on hub with chalk marks two wheel studs apart. Tighten nuts in the
proper sequence and torque to specification. Finally, check lateral runout of rotor to see if lateral
runout is now within specification.
Minimum Rotor Thickness Markings
If lateral runout is not within specification, install a new rotor or reface rotor, being careful to remove
as little rotor material as possible from each side of rotor. Remove equal amounts from each side of
rotor. Do not reduce thickness below minimum thickness marking cast into the un-machined
surface of the rotor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 5714
Checking Rotor For Thickness Variation
Thickness variation measurements of the rotor should be made in conjunction with the lateral
runout measurements. Measure the thickness of the rotor at 12 circumferentially equal points with
a micrometer at a radius approximately 25.4 mm (1 inch) from outer edge of rotor. If thickness
measurements vary by more than 0.013 mm (0.0005 inch), rotor should be removed and
resurfaced, or a new rotor installed. If cracks or burned spots are evident, rotor must be replaced.
Light scoring and/or wear is acceptable. If heavy scoring or warping is evident, the rotor must be
refinished or replaced (See Refinishing/Refacing Rotor). If cracks are evident in the rotor, replace
the rotor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 5715
Brake Rotor/Disc: Service and Repair
Rotor Refinishing Limits Specifications
Rear Rotor Thickness Markings
Fig 6 Refacing Brake Disc
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Disc Brake System > Brake Rotor/Disc > Component
Information > Specifications > Page 5716
Fig 7 Refacing Brake Disc -- Final Finish
PROCEDURES
Any servicing of the rotor requires extreme care to maintain the rotor to within service tolerances to
ensure proper brake action. If the rotor surface is deeply scored or warped, or there is a complaint
of brake roughness or brake pedal pulsation, the rotor should be resurfaced, refaced or replaced.
NOTE: Rotor minimum thickness is usually specified on the rotor hub. The specification is either
stamped or cast into the hub surface.
This marking includes 0.76 mm (0.030 inch) allowable rotor wear beyond the recommended 0.76
mm (0.030 inch) of rotor refacing. The collets, shafts and adapters used on the brake lathe and the
bearing cups in the rotor MUST be clean and free from any chips or contamination. When mounting
the rotor on the brake lathe, strict attention to the brake lathe manufacturer's operating instructions
is required. If the rotor is not mounted properly, the lateral runout will be worse after refacing or
resurfacing than before.
REFACING BRAKE ROTOR
Refacing of the rotor is not required each time the brake pads are replaced. When refacing a rotor
the required 0.08 mm (0.003 inch) Total Indicated Runout (TIR) and 0.013 mm (0.0005 inch)
thickness variation limits MUST BE MAINTAINED. Extreme care in the operation of rotor turning
equipment is required. The use of a double straddle cutter that machines both sides of the rotor at
the same time is highly recommended.
RESURFACING BRAKE ROTOR
This operation can be used when rotor surface is rusty, has lining deposits or excessive lateral
runout or thickness variation is evident. A sanding rotor attachment will remove surface
contamination without removing much rotor material. It will generally follow variations in thickness
that are in the rotor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
Technical Service Bulletin # 05-001-06A Date: 060923
Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
NUMBER: 05-001-06 REV A
GROUP: Brakes
DATE: September 23, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH
9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER.
SUBJECT: Snow/Water Ingestion Into Rear Brake Drum
OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and
possible replacement of the rear brake shoes and drums.
MODELS:
2001 - 2006 (RS) Town & Country/Voyager/Caravan
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (CS) Chrysler Voyager (International Markets)
NOTE:
This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum
brakes) built on or before March 7, 2006 (MDH 0307XX).
SYMPTOM/CONDITION:
While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums
causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead
to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the
vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze
inside of the rear brake drums. When the parking brake has been applied the symptom is more
likely to occur.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5722
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Repair Procedure
1. Raise the vehicle on a suitable hoist.
2. Remove both rear wheel and tire assemblies.
3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the
drum.
4. Create slack in the rear park brake cables. With the park brake pedal in the released position
pull down and rearward on the core of the front park brake cable then install a pair of locking pliers
on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).
5. Lower the vehicle so that it is low enough to access the brake pedal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5723
6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of
travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is
removed from the wheel cylinder.
7. Raise the vehicle.
8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)
9. Remove the adjustment lever from the leading brake shoe.
10. Remove the brake shoe lower return springs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5724
11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly
(Fig. 3)
12. Remove the brake shoe to brake shoe upper return spring.
13. Remove the trailing brake shoe assembly hold down spring and pin.
14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and the park brake actuating strut, (Fig. 4)
15. Remove the automatic adjuster assembly from the leading shoe.
16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake
shoe assembly.
17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate
from the leading brake shoe and install it to the replacement brake shoe.
18. Disconnect the park brake cable from the park brake actuation lever.
19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be
removed unless the speed sensor is removed first.
CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN
REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE
WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN
FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5725
20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park
brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)
21. Disconnect the brake tube from the wheel cylinder.
22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the
wheel cylinder from the vehicle.
23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT
DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY
PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE
HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR
BEARING FAILURE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5726
24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool
8214, (Fig. 6), for RS skip to step 25.
a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of the tool.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special
Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until
the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when
pressing the bearing out of the axle.
c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt
against Special Tool 8214-1.
d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2
against Special Tool 8214-1. Proceed to step 26.
25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458
(Fig. 7)
a. Thread threaded guide pins into hub and bearing mounting holes.
b. Remove the two outboard spring plate bolts.
c. Using the spring plate bolts, install the screw mount, special tool 8458-2.
d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.
e. Place a dab of grease in the dimple of the push plate.
f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the
hub and bearing assembly out of the axle by continuing to tighten the screw.
g. Remove the tool.
h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).
26. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5727
27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual
adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard
the support plate.
28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.
29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange
of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of
the vehicle.
30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing.
Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the
rear axle.
31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).
NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS
ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO
OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH
POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE
REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N
04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97
HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT
REQUIRED.
32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder
opening in the revised brake support plate.
33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque
the 2 mounting bolts to 8 Nm (75 in. lbs.).
34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)
35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to
12 Nm (105 in. lbs.).
36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange
and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.
37. Install the rear park brake cable into its mounting hole in the brake support plate.
38. Install the park brake cable to the park brake actuator lever.
39. Lubricate the eight brake shoe contact areas on the support plate using the required special
Mopar Brake Lubricant p/n 04796269.
40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.
41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing
brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing
brake shoe on the brake support plate.
43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.
44. Install the upper brake shoe to brake shoe return spring.
CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST
BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED
ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC
ADJUSTER WILL BE AFFECTED.
45. Install the tension clip attaching the upper return spring to the automatic adjuster.
46. Install the lower brake shoe to brake shoe return springs.
47. Install the automatic adjuster lever on the leading brake shoe.
48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.
49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic
adjuster assembly.
50. Repeat steps 8 through 48 for the other side rear brake assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5728
51. When all components of both rear brake assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
52. Adjust the rear brakes so they do not interfere with installing the brake drums.
53. Install both rear brake drums. Install the original drums as removed unless their condition
justifies turning or replacement.
54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135
Nm (100 ft. lbs.).
55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is
against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward
rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.
56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against
the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting
lever or distort the lever spring.
57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to
eliminate the drag felt when the tire/wheel assembly is turned.
58. Install the adjusting/inspection hole rubber plug(s) saved in step 26
59. Repeat steps 55 through 58 for the other side rear brake.
60. Perform the base brake bleeding procedure described in the appropriate service manual.
61. Lower the vehicle to the floor.
62. Push the park brake pedal down fully and release to adjust the park brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Page 5729
Backing Plate: Specifications
To Rear Axle Mounting Bolts ...............................................................................................................
................................................. 130 Nm (95 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Page 5730
Backing Plate: Service and Repair
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and
tire. 3. Remove brake drum from hub/bearing. 4. Remove brake shoes from brake support plate. 5.
Disconnect the park brake cable from the park brake actuation lever.
6. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be
removed unless the speed sensor is removed first.
CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on
the tone wheel will result in false ABS cycling and corrosion of the tone wheel.
7. Remove the 4 bolts attaching the hub/ bearing to the flange of the rear axle.
CAUTION: Corrosion may occur between the hub/bearing and the axle. If this occurs the
hub/bearing will be difficult to remove from the axle. If the hub/ bearing will not come out of the axle
by pulling on it by hand, do not pound on the hub/bearing to remove it from the axle. Pounding on
the hub/bearing to remove it from the axle will damage the hub/bearing. This damage will result in
noise or failure of the bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Page 5731
8. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or
equivalent and following procedure to press the
hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and
against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of
Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the bole in the
bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should
be against and supported by the axle plate when pressing the wheel bearing out of the axle. If
Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the
flashing from the hole until tool fits properly.
d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or
equivalent. Tighten bolt against Special Tool 8214-1
or equivalent.
e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special
Tool 8214-1 or equivalents.
9. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Page 5732
10. Using a suitable tool such as a 14 mm box wrench or an aircraft type hose clamp, compress
the flared legs on park brake cable retainer. Then pull
the park brake cable out of brake support plate.
11. Lower vehicle enough to access the brake pedal. 12. Using a brake pedal depressor, move
brake pedal to a position past its first 1 inch of travel. This will prevent brake fluid from draining out
of
master cylinder when brake tube is remove from wheel cylinder.
13. Raise vehicle.
14. Disconnect brake tube from wheel cylinder. 15. Remove the 2 bolts attaching the wheel
cylinder to the brake support plate. 16. Remove the wheel cylinder from the brake support plate.
17. Remove the rear brake support plate from the rear axle.
INSTALL
1. Install the 4 hub/bearing to axle mounting bolts into the mounting holes in the flange of the rear
axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Backing Plate > Component Information
> Technical Service Bulletins > Page 5733
2. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle.
NOTE: When installing the hub/bearing on the rear axle, the bearing is to be installed with the thick
bearing mounting flange pointing down.
3. Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle.
4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Apply sealant
such as Mopar Gasket-In-A-Tube or an equivalent around the wheel cylinder opening in the brake
support plate. 6. Install wheel cylinder onto brake support and tighten the wheel cylinder to brake
support plate attaching bolts to 8 Nm (75 inch lbs.). 7. Install brake tube on rear wheel cylinder.
Tighten tube nut to a torque of 16 Nm (142 inch lbs.). 8. Install the rear wheel speed sensor on the
rear hub/bearing flange. Install the speed sensor attaching bolt and tighten to a torque of 12 Nm
(105
inch lbs.).
9. Install the rear park brake cable into its mounting hole in the rear brake support plate.
10. Install the park brake cable on the park brake actuation lever. 11. Install the rear brake shoes
on the brake support plate. 12. Install brake drum onto hub/bearing. 13. Install wheel and tire. 14.
Tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 15. Adjust the rear brakes. 16. Bleed the entire
brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Adjuster > Component Information
> Testing and Inspection
Brake Adjuster: Testing and Inspection
ADJUSTER REAR DRUM BRAKE (AUTOMATIC)
The rear drum brakes on this vehicle automatically adjust, when required, during the normal
operation of the vehicle every time the brakes are applied. Use the following procedure to test the
operation of the automatic adjuster.
Place the vehicle on a hoist with a helper in the driver's seat to apply the brakes. Remove the
access plug from the adjustment hole in each brake support plate to provide visual access of the
brake adjuster star wheel.
Park Brake Cable Equalizer
Remove the park brake cable, for the wheel of the vehicle that is being worked on, from the park
brake cable equalizer. This is required to gain access to the star wheel. If the cable is not removed
from the equalizer, the cable and spring inside of the brake drum is in the way of the star wheel.
To eliminate the condition where maximum adjustment of the rear brake shoes, does not allow the
automatic adjuster to operate when tested, back the star wheel off approximately 30 notches. It will
be necessary to hold the adjuster lever away from the star wheel to permit this adjustment.
Have the helper apply the brakes. Upon application of the brake pedal, the adjuster lever lever
should move down, turning the adjuster star wheel. Thus, a definite rotation of the adjuster star
wheel can be observed if the automatic adjuster is working properly. If one or more adjusters do
not function properly, the respective drum must be removed for adjuster servicing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
Technical Service Bulletin # 05-001-06A Date: 060923
Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
NUMBER: 05-001-06 REV A
GROUP: Brakes
DATE: September 23, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH
9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER.
SUBJECT: Snow/Water Ingestion Into Rear Brake Drum
OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and
possible replacement of the rear brake shoes and drums.
MODELS:
2001 - 2006 (RS) Town & Country/Voyager/Caravan
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (CS) Chrysler Voyager (International Markets)
NOTE:
This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum
brakes) built on or before March 7, 2006 (MDH 0307XX).
SYMPTOM/CONDITION:
While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums
causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead
to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the
vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze
inside of the rear brake drums. When the parking brake has been applied the symptom is more
likely to occur.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5741
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Repair Procedure
1. Raise the vehicle on a suitable hoist.
2. Remove both rear wheel and tire assemblies.
3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the
drum.
4. Create slack in the rear park brake cables. With the park brake pedal in the released position
pull down and rearward on the core of the front park brake cable then install a pair of locking pliers
on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).
5. Lower the vehicle so that it is low enough to access the brake pedal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5742
6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of
travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is
removed from the wheel cylinder.
7. Raise the vehicle.
8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)
9. Remove the adjustment lever from the leading brake shoe.
10. Remove the brake shoe lower return springs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5743
11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly
(Fig. 3)
12. Remove the brake shoe to brake shoe upper return spring.
13. Remove the trailing brake shoe assembly hold down spring and pin.
14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and the park brake actuating strut, (Fig. 4)
15. Remove the automatic adjuster assembly from the leading shoe.
16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake
shoe assembly.
17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate
from the leading brake shoe and install it to the replacement brake shoe.
18. Disconnect the park brake cable from the park brake actuation lever.
19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be
removed unless the speed sensor is removed first.
CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN
REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE
WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN
FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5744
20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park
brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)
21. Disconnect the brake tube from the wheel cylinder.
22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the
wheel cylinder from the vehicle.
23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT
DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY
PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE
HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR
BEARING FAILURE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5745
24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool
8214, (Fig. 6), for RS skip to step 25.
a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of the tool.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special
Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until
the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when
pressing the bearing out of the axle.
c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt
against Special Tool 8214-1.
d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2
against Special Tool 8214-1. Proceed to step 26.
25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458
(Fig. 7)
a. Thread threaded guide pins into hub and bearing mounting holes.
b. Remove the two outboard spring plate bolts.
c. Using the spring plate bolts, install the screw mount, special tool 8458-2.
d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.
e. Place a dab of grease in the dimple of the push plate.
f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the
hub and bearing assembly out of the axle by continuing to tighten the screw.
g. Remove the tool.
h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).
26. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5746
27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual
adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard
the support plate.
28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.
29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange
of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of
the vehicle.
30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing.
Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the
rear axle.
31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).
NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS
ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO
OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH
POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE
REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N
04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97
HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT
REQUIRED.
32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder
opening in the revised brake support plate.
33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque
the 2 mounting bolts to 8 Nm (75 in. lbs.).
34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)
35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to
12 Nm (105 in. lbs.).
36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange
and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.
37. Install the rear park brake cable into its mounting hole in the brake support plate.
38. Install the park brake cable to the park brake actuator lever.
39. Lubricate the eight brake shoe contact areas on the support plate using the required special
Mopar Brake Lubricant p/n 04796269.
40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.
41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing
brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing
brake shoe on the brake support plate.
43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.
44. Install the upper brake shoe to brake shoe return spring.
CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST
BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED
ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC
ADJUSTER WILL BE AFFECTED.
45. Install the tension clip attaching the upper return spring to the automatic adjuster.
46. Install the lower brake shoe to brake shoe return springs.
47. Install the automatic adjuster lever on the leading brake shoe.
48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.
49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic
adjuster assembly.
50. Repeat steps 8 through 48 for the other side rear brake assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5747
51. When all components of both rear brake assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
52. Adjust the rear brakes so they do not interfere with installing the brake drums.
53. Install both rear brake drums. Install the original drums as removed unless their condition
justifies turning or replacement.
54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135
Nm (100 ft. lbs.).
55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is
against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward
rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.
56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against
the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting
lever or distort the lever spring.
57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to
eliminate the drag felt when the tire/wheel assembly is turned.
58. Install the adjusting/inspection hole rubber plug(s) saved in step 26
59. Repeat steps 55 through 58 for the other side rear brake.
60. Perform the base brake bleeding procedure described in the appropriate service manual.
61. Lower the vehicle to the floor.
62. Push the park brake pedal down fully and release to adjust the park brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Technical Service Bulletins > Page 5748
Brake Drum: Specifications Brake Drum Specifications
Brake Drum Specifications
DRUM DIAMETER 250 mm (9.84 in.)
DRUM DIAMETER (Maximum) Cast/stamped into outside surface of drum
This marking includes 0.76 mm (0.030 inch) for allowable
drum wear beyond the recommended 1.52 mm (0.060 inch) of
drum refacing.
DIAMETER VARIATION (Maximum) 0.090 mm (0.004 in.)
DRUM RUNOUT (on lathe) 0.15 mm (0.006 in.)
INITIAL DRUM MACHINING CUTS 0.13 mm (0.005 in.)
Initial machining cuts should be limited to 0.13 mm (0.005
in.) at a time as heavier feed rates can produce taper and
surface variation.
FINISH DRUM MACHINING CUTS 0.0254 mm (0.001 in.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal and Installation
Brake Drum: Service and Repair Brake Drum Removal and Installation
REMOVE
Park Brake Cable Equalizer
1. Remove the tire and wheel assembly from the vehicle. Remove the park brake cable, for the
wheel of the vehicle that is being worked on, from the
park brake cable equalizer. This is required to gain access to the star wheel. If the cable is not
removed from the equalizer, the cable and spring inside of the brake drum is in the way of the star
wheel.
2. Remove the rear brake shoe adjusting hole cover plug. 3. Insert a thin screwdriver into brake
adjusting hole and hold adjusting lever away from notches of adjusting screw star wheel. 4. Insert
Tool C-3784 or equivalent into brake adjusting hole and engage notches of brake adjusting screw
star wheel. Release brake adjustment by
prying down with adjusting tool.
5. Remove rear brake drum from rear hub/bearing assembly.
INSTALL
1. Adjust brake shoes assemblies so as not to interfere with brake drum installation. 2. Install the
rear brake drums on the hubs. 3. Adjust rear brake shoes. 4. Install the removed park brake cable
back on the park brake cable equalizer 5. Install wheel and tire. 6. Tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to half specification. Then repeat the tightening
sequence to the
full specified torque of 130 Nm (95 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Drum > Component Information >
Service and Repair > Brake Drum Removal and Installation > Page 5751
Brake Drum: Service and Repair Brake Drum Refinishing
Measure the runout and diameter of the rear brake using only accurate measuring equipment.
There should be no variation in the drum diameter greater than 0.090 mm (0.004 inch). Drum
runout should not exceed 0.15 mm (0.006 inch) out of round. If the drum runout or diameter
variation exceed these values the drum should be refaced. For best results in eliminating the
irregularities that cause brake roughness and surge, the amount of material removed during a
single cut should be limited to 0.13 mm (0.005 inch). When the entire braking surface has been
cleaned. A final cut of 0.0254 mm (0.001 inch) will assure a good drum surface providing the
equipment used is capable of the precision required for resurfacing brake drums. Deeper cuts are
permissible for the sole purpose of removing deep score marks. Do not reface more than 1.52 mm
(0.060 inch) over the standard drum diameter.
All drums will show markings of maximum allowable diameter. For example, a drum will have a
marking of MAX. DIA. 251.55 mm (9.90 inch). This marking includes 0.76 mm (0.030 inch) for
allowable drum wear beyond the recommended 1.52 mm (0.060 inch) of drum refacing
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
Technical Service Bulletin # 05-001-06A Date: 060923
Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion
NUMBER: 05-001-06 REV A
GROUP: Brakes
DATE: September 23, 2006
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 05-001-06, DATED MARCH
9, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDES A REVISED PART NUMBER.
SUBJECT: Snow/Water Ingestion Into Rear Brake Drum
OVERVIEW: This bulletin involves installing a revised rear drum brake support (backing) plate and
possible replacement of the rear brake shoes and drums.
MODELS:
2001 - 2006 (RS) Town & Country/Voyager/Caravan
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (CS) Chrysler Voyager (International Markets)
NOTE:
This bulletin applies to vehicles equipped with sales codes BRA, BRB, or BRV (front disc/rear drum
brakes) built on or before March 7, 2006 (MDH 0307XX).
SYMPTOM/CONDITION:
While driving through deep or blowing snow/water, the snow/water may enter the rear brake drums
causing rust to develop on the rear brake drum and shoe friction surfaces. This condition can lead
to temporary freezing of the rear brake linings to the drums. This symptom is experienced after the
vehicle has been parked in below freezing temperatures long enough for the snow/water to freeze
inside of the rear brake drums. When the parking brake has been applied the symptom is more
likely to occur.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5756
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Repair Procedure
1. Raise the vehicle on a suitable hoist.
2. Remove both rear wheel and tire assemblies.
3. Remove both brake drums. It may be necessary to adjust the rear shoes to aid in removing the
drum.
4. Create slack in the rear park brake cables. With the park brake pedal in the released position
pull down and rearward on the core of the front park brake cable then install a pair of locking pliers
on the core of the front park brake cable just rearward of the rear body outrigger bracket (Fig. 1).
5. Lower the vehicle so that it is low enough to access the brake pedal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5757
6. Use a brake pedal depressor to move and hold the brake pedal to a position past the first inch of
travel. This will prevent brake fluid from draining out of the master cylinder when the brake tube is
removed from the wheel cylinder.
7. Raise the vehicle.
8. Remove the adjustment lever spring from the adjustment lever and leading brake shoe, (Fig. 2)
9. Remove the adjustment lever from the leading brake shoe.
10. Remove the brake shoe lower return springs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5758
11. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly
(Fig. 3)
12. Remove the brake shoe to brake shoe upper return spring.
13. Remove the trailing brake shoe assembly hold down spring and pin.
14. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and the park brake actuating strut, (Fig. 4)
15. Remove the automatic adjuster assembly from the leading shoe.
16. Remove the leading brake shoe assembly hold down spring and pin. Remove the leading brake
shoe assembly.
17. Replace the rear brake shoes using p/n 05183395AA. Remove the park brake actuator plate
from the leading brake shoe and install it to the replacement brake shoe.
18. Disconnect the park brake cable from the park brake actuation lever.
19. Remove the rear wheel speed sensor if so equipped. The hub/bearing assembly cannot be
removed unless the speed sensor is removed first.
CAUTION:
WHEN WORKING IN THE AREA OF THE REAR HUB/BEARING ASSEMBLY AND WHEN
REMOVING IT FROM THE REAR AXLE, CARE MUST BE USED SO THE TEETH OF THE TONE
WHEEL ARE NOT DAMAGED. DAMAGE TO THE TONE WHEEL TEETH WILL RESULT IN
FALSE ABS CYCLING AND CORROSION OF THE TONE WHEEL.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5759
20. Using a suitable tool such as a 14 mm box end wrench compress the flared legs on the park
brake cable retainer. Then pull the park brake cable out of the support plate (Fig. 5)
21. Disconnect the brake tube from the wheel cylinder.
22. Remove the two bolts attaching the wheel cylinder to the brake support plate and separate the
wheel cylinder from the vehicle.
23. Remove the 4 bolts attaching the hub/bearing assembly to the flange of the rear axle.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE MAKING IT
DIFFICULT TO REMOVE. IF THE HUB/BEARING WILL NOT COME OUT OF THE AXLE BY
PULLING ON IT BY HAND DO NOT HIT/POUND THE HUB/BEARING. POUNDING ON THE
HUB/BEARING WILL CAUSE DAMAGE TO THE BEARING THAT RESULTS IN NOISE OR
BEARING FAILURE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5760
24. If the hub/bearing cannot be removed by hand, for GS/NS vehicles use remover Special Tool
8214, (Fig. 6), for RS skip to step 25.
a. Place Special Tool 8214-1 over the tone wheel and against the cast flange of the hub/bearing.
Put a dab of grease in the bolt pilot hole on the back of the tool.
b. Insert Special Tool 8214-2 into the hole in the bottom of the end casting on the axle. If Special
Tool 8214-2 will not fit into the hole in the end casting, file or grind the flashing from the hole until
the tool fits properly. Special Tool 8214-2 must be against and supported by the axle plate when
pressing the bearing out of the axle.
c. Align bolt in Special Tool 8214-2 with the pilot hole in Special Tool 8214-1. Tighten the bolt
against Special Tool 8214-1.
d. Press the hub/bearing out of the axle by continuing to tighten the bolt in Special Tool 8214-2
against Special Tool 8214-1. Proceed to step 26.
25. If the hub/bearing cannot be removed by hand, for RS vehicles use remover Special Tool 8458
(Fig. 7)
a. Thread threaded guide pins into hub and bearing mounting holes.
b. Remove the two outboard spring plate bolts.
c. Using the spring plate bolts, install the screw mount, special tool 8458-2.
d. Place push plate, special tool 8458-1, on the ends of the threaded guide pins.
e. Place a dab of grease in the dimple of the push plate.
f. Tighten the forcing screw, special tool 8458-3, against the dimple in the push plate and press the
hub and bearing assembly out of the axle by continuing to tighten the screw.
g. Remove the tool.
h. Reinstall the two outboard spring plate bolts and torque to 102 Nm (75 ft. lbs.).
26. Remove the hub/bearing from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5761
27. Remove the brake support plate from the vehicle. Remove the rubber plug(s) in the manual
adjuster and lining inspection slot(s) as equipped, for use in the replacement support plate. Discard
the support plate.
28. Insert the 4 hub/bearing mounting bolts into the holes in the flange of the rear axle.
29. Install the revised brake support plate, p/n 05016612/3AA on the 4 bolts inserted in the flange
of the rear axle, make sure the park brake cable hole in the support plate faces toward the front of
the vehicle.
30. Align the hub/bearing with the 4 mounting bolts and finger tighten the bolts into the hub/bearing.
Tighten the 4 bolts in a crisscross pattern until the hub/bearing is fully seated into the flange of the
rear axle.
31. Torque the 4 hub/bearing mounting bolts to 129 Nm (95 ft. lbs.).
NOTE:
FOR NS-VEHICLES BUILT PRIOR TO SEPT. 27, 1996 (MDH 0927XX) AT THE ST. LOUIS
ASSEMBLY PLANT (LETTER "B" IN THE 11TH POSITION OF THE VIN) AND BUILT PRIOR TO
OCT. 28 1996 (MDH 1028XX) AT THE WINDSOR ASSEMBLY PLANT (LETTER "R" IN THE 11TH
POSITION OF THE VIN), THAT HAVE THEIR ORIGINAL REAR BRAKE COMPONENTS, IF THE
REAR BRAKE SHOES REQUIRE REPLACEMENT, WHEEL CYLINDERS (13/16 IN.), P/N
04883830AA, MUST ALSO BE INSTALLED. IF TSB 05-06-96, 05-06-96 REV.A OR 05-01-97
HAVE BEEN PERFORMED ON THE VEHICLE, WHEEL CYLINDER REPLACEMENT IS NOT
REQUIRED.
32. Apply a sealant such as Mopar RTV, p/n 05010884AA, or equivalent around the wheel cylinder
opening in the revised brake support plate.
33. Attach the wheel cylinder to the revised brake support plate before the sealant cures, torque
the 2 mounting bolts to 8 Nm (75 in. lbs.).
34. Install the brake tube into the wheel cylinder and torque the tube nut to 16 Nm (142 in. lbs.)
35. Install the rear wheel speed sensor if so equipped. CS/NS vehicles: torque the attaching bolt to
12 Nm (105 in. lbs.).
36. For GS/NS without ABS and all RS vehicles fill any existing gap between the bearing flange
and the ABS sensor hole in the support plate with Mopar RTV sealant, p/n 05010884AA.
37. Install the rear park brake cable into its mounting hole in the brake support plate.
38. Install the park brake cable to the park brake actuator lever.
39. Lubricate the eight brake shoe contact areas on the support plate using the required special
Mopar Brake Lubricant p/n 04796269.
40. Install the leading brake shoe, hold down, pin and spring onto the brake support plate.
41. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
42. Install the automatic adjuster assembly on the leading brake shoe. Then install the trailing
brake shoe on the park brake actuator lever and park brake actuator strut. Position the trailing
brake shoe on the brake support plate.
43. Install the trailing brake shoe hold down, pin and spring onto the brake support plate.
44. Install the upper brake shoe to brake shoe return spring.
CAUTION:
WHEN INSTALLING THE TENSION CLIP ON THE AUTOMATIC ADJUSTER, THE CLIP MUST
BE LOCATED ON THE THREADED AREA OF THE ADJUSTER ASSEMBLY. IF IT IS LOCATED
ON THE NON-THREADED AREA OF THE ADJUSTER, THE FUNCTION OF THE AUTOMATIC
ADJUSTER WILL BE AFFECTED.
45. Install the tension clip attaching the upper return spring to the automatic adjuster.
46. Install the lower brake shoe to brake shoe return springs.
47. Install the automatic adjuster lever on the leading brake shoe.
48. Install the actuating spring on the automatic adjuster lever and the leading brake shoe.
49. Verify the automatic adjuster lever has positive contact with the star wheel on the automatic
adjuster assembly.
50. Repeat steps 8 through 48 for the other side rear brake assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Brakes - Rear Brake Drum Freezing/Water/Snow Ingestion > Page 5762
51. When all components of both rear brake assemblies are correctly and fully installed, remove
the locking pliers from the front park brake cable.
52. Adjust the rear brakes so they do not interfere with installing the brake drums.
53. Install both rear brake drums. Install the original drums as removed unless their condition
justifies turning or replacement.
54. Install both rear tire/wheel assemblies. Torque the lug nuts using a crisscross pattern to 135
Nm (100 ft. lbs.).
55. Insert a thin flat blade screwdriver through the adjusting hole in the support plate until it is
against the star wheel of the adjuster assembly. Move the handle of the screwdriver upward
rotating the star wheel until slight drag is felt when the tire/wheel assembly is turned.
56. Insert a second screwdriver or piece of stiff wire into the brake adjusting hole and push against
the adjuster lever to disengage it from the star wheel. Care should be taken not bend the adjusting
lever or distort the lever spring.
57. While the adjuster lever is disengaged from the star wheel turn the star wheel just enough to
eliminate the drag felt when the tire/wheel assembly is turned.
58. Install the adjusting/inspection hole rubber plug(s) saved in step 26
59. Repeat steps 55 through 58 for the other side rear brake.
60. Perform the base brake bleeding procedure described in the appropriate service manual.
61. Lower the vehicle to the floor.
62. Push the park brake pedal down fully and release to adjust the park brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Technical Service Bulletins > Page 5763
Brake Shoe: Specifications
As a general rule, riveted brake shoes should be replaced when worn to within 0.78 mm (1/32 inch)
of the rivet heads.
Bonded linings should be replaced when worn to a thickness of 1.6 mm (1/16 inch).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation
Brake Shoe: Service and Repair Brake Shoe Removal and Installation
Removal
WARNING: Although factory installed brake linings are made from asbestos free materials, some
aftermarket brake lining may contain asbestos. This should be taken into account when servicing a
vehicle's brake system, when aftermarket brake linings may have been installed on the vehicle.
Always wear a respirator when cleaning brake components as asbestos can cause serious bodily
harm such as asbestosis and or cancer. Never clean brake components by using compressed air,
use only a vacuum cleaner specifically designed for the removal of brake dust. If a vacuum cleaner
is not available, clean brake parts using only water-dampened shop towels. Do not create brake
lining dust by sanding brake linings when servicing a vehicle. Dispose of all dust and dirt suspected
of containing asbestos fibers using only sealed airtight bags or containers. Follow all recommended
safety practices; prescribed by the Occupational Safety And Health Administration (OSHA) and the
Environmental Protection Agency (EPA), for handling and disposal of products containing
asbestos.
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove the rear wheel and tire
assemblies from the vehicle. 3. Remove rear brake drum to hub retaining nuts (if equipped). Then
remove rear brake drums from hub and bearing assemblies.
NOTE: When creating slack in the park brake cables by locking out the automatic adjuster, be sure
that the park brake pedal is in the released (most upward) position.
4. Create slack in the rear park brake cables. Slack is created by grabbing exposed section. of front
park brake cable and pulling it down and
rearward. Slack is maintained in the park brake cable by installing a pair of locking pliers on the
park brake cable just rearward of only the rear body outrigger bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5766
5. Remove adjustment lever spring from adjustment lever and front brake shoe.
6. Remove adjustment lever from leading brake shoe.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5767
7. Remove the brake shoe to brake shoe lower return springs.
8. Remove the tension clip attaching the upper return spring to the automatic adjuster assembly.
9. Remove the brake shoe to brake shoe upper return spring.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5768
10. Remove the trailing brake shoe assembly to brake support plate hold down spring and pin from
the brake shoe assembly.
11. Remove the trailing brake shoe assembly from the brake support plate, park brake actuating
lever and park brake actuating strut. Remove the
automatic adjuster assembly from the leading brake shoe.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5769
12. Remove the leading brake shoe assembly to brake support plate hold down spring and pin from
the brake shoe. Remove the leading brake shoe
from the brake support plate.
13. Remove the park brake actuator from the leading brake shoe and transfer to the replacement
brake shoe.
Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5770
1. Lubricate the eight shoe contact areas on the support plate and anchor, using the required
special Mopar Brake Lubricant, P/N 4796269.
2. Install leading brake shoe on brake support plate. Install the leading brake shoe hold down
spring and pin on the brake shoe.
3. Install the park brake actuator strut on the leading brake shoe. Then install the park brake
actuator lever on the strut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5771
4. Install the automatic adjuster screw on the leading brake shoe. Then install the trailing brake
shoe on the park brake actuating lever and park brake
actuating strut. Position trailing brake shoe on brake support plate.
5. Install the brake shoe hold down pin and spring on the trailing brake shoe.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5772
6. Install the brake shoe to brake shoe upper return spring.
CAUTION: When installing the tension clip on the automatic adjuster, it must be located on only the
threaded area of the adjuster assembly. If it is located on a non-threaded area of the adjuster, the
function of the automatic adjuster will be affected.
7. Install the tension clip attaching the upper return spring to the automatic adjuster assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5773
8. Install the brake shoe to brake shoe lower return springs on the brake shoes.
9. Install automatic adjustment lever on the leading brake shoe of the rear brake assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5774
10. Install the actuating spring on the automatic adjustment lever and leading brake shoe
assembly. 11. Verify that the automatic adjuster lever has positive contact with the star wheel on
the automatic adjuster assembly. 12. When all components of both rear brake assemblies are
correctly and fully installed, remove the locking pliers from the front park brake cable. 13. Adjust
brake shoes assemblies so as not to interfere with brake drum installation. 14. Install the rear brake
drums on the hubs. 15. Adjust rear brake shoes. 16. Install the wheel and tire assembly. 17. Push
the park brake pedal to the floor once and release pedal. This will automatically remove the slack
from and correctly adjust the park brake
cables.
18. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half
specification. Then repeat the tightening sequence to the
full specified torque of 130 Nm (95 ft. lbs.).
19. Road test vehicle. The automatic adjuster will continue the brake adjustment during the road
test of the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Brake Shoe > Component Information >
Service and Repair > Brake Shoe Removal and Installation > Page 5775
Brake Shoe: Service and Repair Cleaning and Inspection
1. Remove the tire and wheel assembly from the vehicle
Brake Adjustment Hole Rubber Plug
2. Remove the rear brake adjusting hole cover plug. 3. Insert a thin screwdriver into brake adjusting
hole to hold the adjusting lever away from the notches on the adjusting screw star wheel. 4. Insert
Tool C-3784 or equivalent into brake adjusting hole and engage notches of brake adjusting screw
star wheel. Release brake by prying down
with adjusting tool.
5. Remove the rear brake drum from the rear hub/bearing assembly. 6. Inspect brake lining for
wear, shoe alignment, and or contamination from grease or brake fluid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications
Wheel Cylinder: Specifications
Diameter 3/4 in
To Support Plate Mounting Bolts 75 in.lb
Bleeder Screw 80 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Specifications > Page 5779
Rear Wheel Cylinder (Exploded View)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation
Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation
REMOVE
1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid.)
2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel
cylinder attaching bolts. Then pull wheel cylinder assembly off the brake support plate.
INSTALL
1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in
brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to
brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel
cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on
support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten
wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5782
Wheel Cylinder: Service and Repair Cleaning and Inspection
With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak.
Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel
cylinders should be completely cleaned, inspected and new parts installed.
If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake
shoes must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Drum Brake System > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5783
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
Fig 3 Wheel Cylinder
DISASSEMBLE
To disassemble the wheel cylinders, proceed as follows:
1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite
piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston
that
remain in the wheel cylinder.
3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; (DO NOT USE ANY
PETROLEUM BASE SOLVENTS) clean
thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and
pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.)
4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder
walls that have light scratches, or show signs of
corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the
cylinder walls are caused by piston cups and will not impair operation of cylinder.
ASSEMBLE
Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If
the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install
new boots.
1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the
wheel cylinder cups with only Mopar Protect-A-Cup Lubricant p/n 04883068 and no
substitute.
3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with
open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of
each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of
cylinder. Be careful not to damage boot during installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Base Brake System Bleeding Procedures
Brake Bleeding: Service and Repair Base Brake System Bleeding Procedures
Bleeding Base Brake Hydraulic System
NOTE: This bleeding procedure is only for the vehicle's base brakes hydraulic system. For
bleeding the antilock brakes hydraulic system, refer to the ITT Teves Mark 20 Antilock Brake
System bleeding procedure in antilock brakes.
Pressure Bleeding Procedure
CAUTION:
- Before removing the master cylinder cover, throughly clean the cover and master cylinder fluid
reservoir to prevent dirt and other foreign matter from dropping into the master cylinder fluid
reservoir.
- Use bleeder tank Special Tool C-3496-B with adapter Special Tool 6921 to pressurize the
hydraulic system for bleeding.
- When pressure bleeding the brakes hydraulic system the fluid reservoir filler neck must be
removed from the master cylinder fluid reservoir. Failure to remove the filler neck from the fluid
reservoir, may result in the filler neck separating from the fluid reservoir when the hydraulic system
is pressurized.
Follow pressure bleeder manufacturer's instructions, for use of pressure bleeding equipment.
Air Trapped In Brake System
When bleeding the brake system, some air may be trapped in the brake lines or valves far
upstream, as much as ten feet from the bleeder screw. Therefore, it is essential to have a fast flow
of a large volume of brake fluid when bleeding the brakes to ensure all the air gets out.
1. Remove the filler neck from the master cylinder fluid reservoir.
Pressure Bleeding Cap Installed On Master Cylinder
2. Install the Adapter Master Cylinder Pressure Bleed Cap, Special Tool 6921, or equivalent on the
fluid reservoir of the master cylinder. Attach the
fluid hose from the pressure bleeder to the fitting on Special Tool 6921, or equivalent.
3. Attach a clear plastic hose to the bleeder screw at one wheel and feed the hose into a clear jar
containing fresh brake fluid.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Base Brake System Bleeding Procedures > Page 5789
adequate removal of all trapped air from the brake hydraulic system.
(1st) - Left Rear Wheel (2nd) - Right Front Wheel (3rd) - Right Rear Wheel (4th) - Left Front Wheel
Rear Wheel Cylinder Bleeder Screw
4. Open the left rear wheel bleeder screw at least one full turn or more to obtain an adequate flow
of brake fluid.
CAUTION: Just cracking the bleeder screw often restricts fluid flow, and a slow, weak fluid
discharge will NOT get all the air out.
5. After 4 to 8 ounces of brake fluid has been bled through the hydraulic system, and an air-free
flow is maintained in the hose and jar, this will
indicate a good bleed of the hydraulic system has been obtained.
6. Repeat the procedure at all the other remaining bleeder screws. Then check the pedal for travel.
If pedal travel is excessive or has not been
improved, enough fluid has not passed through the system to expel all the trapped air. Be sure to
monitor the fluid level in the pressure bleeder, so it stays at a proper level so air will not enter the
brake system through the master cylinder.
7. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Bleeding Without A Pressure Bleeder
NOTE: Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
NOTE: To adequately bleed the brakes using the manual bleeding procedure the rear brakes must
be correctly adjusted. Prior to bleeding the brake hydraulic system, be sure the rear brakes are
correctly adjusted.
NOTE: The following wheel sequence should be used when bleeding the brake hydraulic system.
The use of this wheel sequence will ensure adequate removal of all trapped air from the brake
hydraulic system.
- Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed.
4. Repeat steps 1 through 3, four or five times, at each bleeder screw in the required sequence.
This should pass a sufficient amount of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Bleeding > System
Information > Service and Repair > Base Brake System Bleeding Procedures > Page 5790
Brake Bleeding: Service and Repair Antilock Brake System Bleeding Procedures
Bleeding Teves Mark 20 Hydraulic System
The base brake system must be bled anytime air is permitted to enter the hydraulic system, due to
disconnection of brake lines, hoses or components. The ABS system, particularly the HCU, should
only be bled when the HCU is replaced or it is removed from the vehicle, or if there is reason to
believe the HCU has ingested air. Under most circumstances that would require brake bleeding,
only the base brake hydraulic system needs to be bled.
It is important to note that excessive air in the brake system will cause a soft or spongy feeling
brake pedal.
During the brake bleeding procedure, be sure the brake fluid level remains close to the FULL level
in the master cylinder fluid reservoir. Check the fluid level periodically during the bleeding
procedure and add DOT 3 brake fluid as required.
The ITT Teves Mark 20 ABS must be bled as two independent braking systems. The non ABS
portion of the brake system is to be bled the same as any non ABS system. This brake system can
be either pressure bled or manually bled.
The ABS portion of the brake system MUST be bled separately. This bleeding procedure requires
the use of the DRB Diagnostic Tester and the bleeding sequence procedure outlined below.
ABS BLEEDING PROCEDURE
When bleeding the ABS system, the following bleeding sequence MUST be followed to insure
complete and adequate bleeding. The ABS system can be bled using a manual bleeding procedure
or standard pressure bleeding equipment.
If the brake system is to be bled using pressurized bleeding equipment, refer to Bleeding Base
Brakes. 1. Assemble and install all brake system components on the vehicle making sure all
hydraulic fluid lines are installed and properly torqued. 2. Connect the DRB Diagnostics Tester to
the diagnostics connector. The Teves Mark 20 ABS diagnostic connector is located under the
instrument panel to the left of the steering column cover.
3. Using the DRB, check to make sure the Controller Antilock Brake (CAB) does not have any fault
codes stored. If it does, remove them using
the DRB.
WARNING: When bleeding the brake system wear safety glasses. A clear bleed tube must be
attached to the bleeder screws and submerged in a clear container filled part way with clean brake
fluid. Direct the flow of brake fluid away from the painted surfaces of the vehicle. Brake fluid at high
pressure may come out of the bleeder screws when opened.
4. Bleed the base brake system using the standard pressure or manual bleeding procedure. 5.
Using the DRB, go to the "Bleed ABS" routine. Apply the brake pedal firmly and initiate the "Bleed
ABS" cycle one time. Release the brake
pedal.
6. Bleed the base brake system again, as in step Step 4 above. 7. Repeat steps Step 5 and Step 6
above until brake fluid flows clear and is free of any air bubbles. Check brake fluid level in reservoir
periodically to prevent reservoir from running low on brake fluid.
8. Test drive the vehicle to be sure brakes are operating correctly and that the brake pedal does
not feel spongy.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5799
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5800
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5801
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5802
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Customer Interest for Brake Caliper: > 05-003-01 > Apr > 01 > Brakes Howl/Moan From The Rear > Page 5803
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear
Technical Service Bulletin # 05-003-01 Date: 010420
Brakes - Howl/Moan From The Rear
NUMBER: 05-003-01
GROUP: Brakes
DATE: Apr. 20, 2001
SUBJECT: Off Pedal Rear Brake Howl/Moan
OVERVIEW: This bulletin involves replacing the rear disc brake adapters.
MODELS: 1997 - 2000
(NS) Voyager/Caravan/Town & Country
1997 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Voyager/Caravan/Town & Country
2001 (RG) Chrysler Voyager (International Markets)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ALL WHEEL DRIVE (AWD).
SYMPTOM/CONDITION: During low speed and/or low speed turns such as a parking lot
maneuver, with no brake pedal pressure applied, a low frequency howl/moan noise is heard from
the rear brake area.
DIAGNOSIS: If the vehicle operator describes the Symptom/Condition above, perform the Repair
Procedure.
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: Could be one or more
Repair Procedure
1. Apply the parking brake and raise the vehicle on an appropriate hoist.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 5809
2. Remove right rear tire and wheel assembly.
3. Remove the cotter pin, nut retainer, and spring washer the from the stub shaft on the outer C/V
joint (Fig. 1).
4. Remove the hub nut and washer from the stub shaft of the outer CV joint.
5. Mark the driveshaft inner joint location to the rear driveline module flange.
6. Remove the 6 bolts mounting the driveshaft inner joint to the output shaft of the rear driveline
module (Fig. 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 5810
7. Remove the wheel speed sensor from the rear hub/bearing (Fig. 3).
8. Remove the driveshaft from the rear driveline module and hub/bearing. The driveshaft is
removed by first compressing the inner joint on the driveshaft and removing it from the driveline
module. Then, slide the outer joint of the driveshaft out of the hub and bearing.
9. Release the parking brake.
10. Create slack in the rear parking brake cables by locking out the automatic adjuster as
described. Grasp the exposed section of the front park brake cable and pull downward on it. Then
install a pair of locking pliers on the front brake cable just rearward of the second body out rigger
bracket (Fig. 4).
11. Remove the park brake cable from the adapter by:
a. NS/GS vehicles: removing and discarding the horseshoe clip from the retainer on the end of the
park brake cable.
b. RS/RG vehicles: removing the park brake mounting bolt.
12. Remove the end of the park brake cable from the actuator lever on the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 5811
13. Remove the park brake cable from adapter by using a 1/2" wrench slipped over the park brake
cable retainer as show in (Fig. 5) to compress the locking tabs on the park brake cable retainer.
14. Remove the disc brake caliper to adapter guide pin bolts.
15. Remove caliper from the adapter using the following procedure: a.
Rotate rear of caliper up.
b. Pull the front of the caliper and the outboard brake shoe anti-rattle clip out from under the front
abutment on the adapter.
16. Support the caliper to prevent the weight of the caliper from damaging the flexible brake hose.
17. Remove the rotor from the hub/bearing.
18. Remove the four hub/bearing to axle mounting bolts.
CAUTION:
CORROSION MAY OCCUR BETWEEN THE HUB/BEARING AND THE AXLE. IF THIS OCCURS
THE HUB/BEARING WILL BE DIFFICULT TO REMOVE FROM THE AXLE. IF THE
HUB/BEARING WILL NOT COME OUT OF THE AXLE BY PULLING ON IT BY HAND, DO NOT
POUND ON THE HUB/BEARING WILL DAMAGE THE HUB/BEARING. TO REMOVE A
HUB/BEARING WHICH IS CORRODED TO THE AXLE, LIGHTLY TAP ON THE DISC BRAKE
CALIPER ADAPTER USING A SOFT FACE HAMMER. THIS WILL REMOVE BOTH THE DISC
BRAKE CALIPER ADAPTER AND THE HUB/BEARING FROM THE AXLE. THE HUB/BEARING
WILL THEN NEED TO BE REMOVED FROM THE CALIPER ADAPTER.
19. Remove the hub/bearing from the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 5812
20. If the disc brake caliper adapter and hub/bearing were removed as an assembly and the two
cannot be separated by hand, use the following procedure:
a. With a helper supporting the caliper adapter in his hands, position Remover, Special Tool 8214-1
on the cast housing of the hub/bearing (Fig. 6)
NOTE:
DO NOT POSITION SPECIAL TOOL ON THE INNER RACE OF THE HUB/BEARING.
b. Lightly strike Remover Special Tool 8214-1 with a hammer to remove the hub/bearing from the
caliper adapter.
21. Using the parking brake anchor boss on the adapter as a clamping point, place the adapter in a
vice. Inspect the parking brake hardware (shoe, return springs, adjuster) for damage and wear. Any
part that is damaged or worn must be replaced by new parts.
22. Remove the park brake hardware (including the rubber access plug) from the adapter and
install park brake hardware on the new adapter.
23. Install the new adapter on the axle.
24. Install the hub/bearing on the end of the axle.
25. Install the hub/bearing mounting bolts. In a progressive crisscross pattern, tighten the 4
mounting bolts until the caliper adapter and hub/bearing are squarely seated against the axle.
Tighten mounting bolts to a torque of 129 Nm (95 ft. lbs.).
26. Install the wheel speed sensor on the hub/bearing and adapter (Fig. 3) and torque attaching
bolt to 12 Nm (105 in. lbs.).
27. Using the alignment mark from step 5, install driveshaft in hub/bearing and on output shaft of
rear drive line module. Driveshaft is installed by first sliding the outer joint of the driveshaft into the
hub/bearing and then compressing the inner joint on the driveshaft and installing it on the output
shaft of the driveline module. Do not tighten mounting bolts at this time.
28. Install the park brake cable into its mounting hole in the adapter.
NOTE:
BE SURE ALL THE LOCKING TABS ON THE PARK BRAKE CABLE RETAINER ARE
EXPANDED OUT TO ENSURE THE CABLE WILL NOT PULL OUT OF THE ADAPTER.
29. Install the end of the park brake cable on the park brake actuator lever.
30. For NS/GS vehicles, install a NEW horseshoe clip on the park brake cable retainer. The
horseshoe clip must be installed with the curved end of the clip pointing straight up and the edge of
the curved end facing the rear of the vehicle. For RS/RG vehicles, install the park brake cable
mounting bolt to the adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Brake Caliper: > 05-003-01 > Apr > 01 >
Brakes - Howl/Moan From The Rear > Page 5813
31. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, adjust the rear park brake
shoe to park brake drum clearance.
32. Install rotor on hub/bearing.
33. Carefully lower the disc brake caliper and brake shoes over the rotor and onto the caliper
adapter by reversing the removal procedure in step 15.
CAUTION:
WHEN INSTALLING THE GUIDE PIN BOLTS, EXTREME CAUTION SHOULD BE TAKEN NOT
TO CROSS-THREAD THE CALIPER GUIDE PIN BOLTS.
34. Apply brake grease p/n J8993704 to caliper guide pin bolts and install caliper guide pin bolts.
Torque to 22 Nm (192 in. lbs.).
35. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint.
36. Remove the locking pliers from the park brake cable (Fig. 4) and lower the vehicle.
37. Set the parking brake. This is required to keep the driveshaft from rotating when tightening and
torquing the hub nut and driveshaft inner joint to driveline module mounting bolts.
38. Raise the vehicle.
39. Tighten the driveshaft inner joint to driveline module output shaft mounting bolts (Fig. 2) to a
torque of 61 Nm (45 ft. lbs.).
40. Tighten the outer C/V joint hub nut to a torque of 244 Nm (180 ft. lbs.).
41. Install the spring washer, nut retainer and a new cotter pin on the stub shaft of the outer C/V
joint.
42. Install tire and wheel assembly.
43. Tighten wheel mounting stud nuts in a crisscross sequence until all nuts are torqued to half
specification. Then repeat the tighten sequence to full torque of 135 Nm (100 ft. lbs.).
44. Replace the left rear adapter using steps 2 through 43.
45. Lower the vehicle.
46. Fully apply and release the park brake pedal one time. This will seat and correctly adjust the
park brake cables.
CAUTION:
BEFORE MOVING THE VEHICLE, PUMP THE BRAKE PEDAL SEVERAL TIMES TO INSURE
THE VEHICLE HAS A FIRM BRAKE PEDAL TO ADEQUATELY STOP THE VEHICLE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Page 5814
Brake Caliper: Specifications
Bore Diameter 60 mm
Caliper Mounting Bolts 16 ft.lb
Guide Pin Bolts 30 ft.lb
Bleeder Screw 125 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Technical Service Bulletins > Page 5815
Brake Caliper: Testing and Inspection
CLEANING AND INSPECTION
Check for brake fluid leaks in and around dust boot area and inboard brake pad, and for any
ruptures, brittleness or damage to the piston dust boot. If the dust boot is damaged, or a fluid leak
is visible, disassemble caliper assembly and install a new piston seal and dust boot, and piston if
scored.
Check the guide pin dust boots to determine if they are in good condition. Replace if they are
damaged, dry, or found to be brittle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation
Brake Caliper: Service and Repair Removal and Installation
Front
CAUTION: During service procedures, grease or any other foreign material must be kept off brake
shoe assemblies, and braking surfaces of brake drum and external surfaces of hub/bearing
assembly.
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove front wheel and tire assemblies.
3. Remove the 2 caliper to steering knuckle guide pin bolts.
Caliper Assembly Mounting On Steering Knuckle (Typical)
4. Remove caliper from steering knuckle, by first rotating free end of caliper away from steering
knuckle. Then slide opposite end of caliper out from
under machined abutment on steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5818
Storing Front Disc Brake Caliper
5. Support caliper firmly to prevent weight of caliper from being supported by the brake fluid flex
hose. Supporting weight of caliper by the brake
fluid flex hose, can damage the flexible brake hose.
INSTALL
1. Lubricate both steering knuckle abutments with a liberal amount of Mopar Multipurpose
Lubricant, or equivalent.
CAUTION: Use care when installing the caliper assembly onto the steering knuckle, so the seals
on the caliper guide pin bushings do not get damaged by the steering knuckle bosses.
2. Carefully position caliper and brake pad assemblies over brake rotor by hooking lower or upper
end of caliper over the machined abutment on
steering knuckle. Then rotate caliper into position at the top of the steering knuckle. Make sure that
caliper guide pin bolts, bushings and sleeves are clear of the steering knuckle bosses.
3. Install the caliper guide pin bolts and tighten to a torque of 55 Nm (40 ft. lbs.). Extreme caution
should be taken not to cross thread the caliper
guide pin bolts.
4. Install the wheel and tire assembly 5. Using a torque wrench, tighten the wheel mounting stud
nuts in proper sequence until all nuts are torqued to half specification. Then repeat the
tightening sequence to the full specified torque of 135 Nm (100 ft. lbs.).
6. Remove jackstands or lower hoist. 7. Before moving vehicle, pump the brake pedal several
times to insure the vehicle has a firm brake pedal.
Rear
GENERAL INFORMATION
During service procedures, grease or any other foreign material must be kept off brake shoe
assemblies, and braking surfaces of rotor.
Handling of the rotor and caliper, must be done in such a way as to avoid damage to the rotor and
scratching or nicking of lining on the brake shoes.
If inspection reveals that the caliper piston seal is leaking, it MUST be replaced immediately.
During removal and installation of a wheel and tire assembly, use care not to strike the caliper.
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear wheel and tire assemblies
from vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5819
Removing Caliper Guide Pin Bolts
3. Remove the disc brake caliper to adapter guide pin bolts.
Removing/Installing Caliper
4. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Correctly Supported Caliper
5. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose.
INSTALL
NOTE: Step 1 below is only required when installing the disc brake caliper after new brake shoes
have been installed.
1. Completely retract caliper piston back into piston bore of caliper assembly. 2. Lubricate both
adapter abutments with a liberal amount of Mopar Multipurpose Lubricant, or equivalent.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5820
3. If removed, install the rear rotor on the hub, making sure it is squarely seated on the face of the
hub.
CAUTION: Use care when installing the caliper assembly onto the adapter, so the caliper guide pin
bushings do not get damaged by the mounting bosses.
4. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse
procedure for removal.
CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the
caliper guide pin bolts.
5. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch lbs.).
6. Install the wheel and tire assembly. 7. Tighten the wheel mounting stud nuts in proper sequence
until all nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
8. Remove jackstands or lower hoist.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop vehicle.
9. Road test the vehicle and make several stops to wear off any foreign material on the brakes and
to seat the brake shoe linings.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5821
Brake Caliper: Service and Repair Disassembly and Assembly
Disassembly and Assembly
DISASSEMBLY
WARNING: Under no condition should air pressure ever be used to remove a piston from a caliper
bore. Personal injury could result from such a practice.
1. Remove caliper from brake rotor. Hang assembly on a wire hook away from rotor, so hydraulic
fluid cannot get on rotor. Place a small piece of
wood between the piston and caliper fingers.
2. Carefully depress brake pedal to hydraulically push piston out of bore. Then apply and hold
down the brake pedal to any position beyond the First
inch of pedal travel. This will prevent loss of brake fluid from the master cylinder.
3. If both front caliper pistons are to be removed, disconnect brake tube at flexible brake hose at
frame rail. Plug brake tube and remove piston fram
opposite caliper using the same process as above for the first piston removal.
4. Disconnect the brake fluid flex hose from the caliper assembly.
CAUTION: Do not use excessive force when clamping caliper in vise. Excessive vise pressure will
cause bore distortion and binding of piston.
5. To disassemble caliper, mount in a vise equipped with protective jaws. 6. Remove guide pin
sleeves and guide pin bushings.
Fig. 10 Dust Boot Removal
7. Remove the piston dust boot from the caliper and discard.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5822
Removing Piston Seal From Caliper
8. Using a soft tool, such as a plastic trim stick, work piston seal out of its groove in caliper piston
bore. Discard old seal. Do not use a screw driver
or other metal tool for this operation, because of the possibility of scratching piston bore or burring
edges of seal groove.
9. Clean all parts using alcohol or a suitable solvent and wipe dry using only a lint free cloth. No lint
residue can remain in caliper bore. Clean out all
drilled passages and bores. Whenever a caliper has been disassembled, a new boot and seal must
be installed at assembly.
Honing Brake Caliper Piston Bore
10. Inspect the piston bore for scoring or pitting. Bores that show light scratches or corrosion can
usually be cleared of the light scratches or corrosion
using crocus cloth. Bores that have deep scratches or scoring should be honed. Use Caliper Hone,
Special Tool C-4095, or equivalent providing the diameter of the bore is not increased more than
0.0254 mm (0.001 inch).
11. If the bore does not clean up within this specification, a new caliper housing should be installed.
Install a new piston if the old one is pitted or
scored.
NOTE: When using Caliper Honing Tool, Special Tool C-4095, coat the stones and bore with brake
fluid. After honing the bore, carefully clean the seal and boot grooves with a stiff non-metallic rotary
brush.
NOTE: Use extreme care in cleaning the caliper after honing. Remove all dirt and grit by flushing
the caliper with brake fluid; wipe dry with a clean, lint free cloth and then clean a second time.
CAUTION: When inspecting caliper piston, do not use anything but solvents to clean piston
surface. If surface of piston cannot be cleaned using only solvents, piston must be replaced.
12. Inspect caliper piston for pitting, scratches, or any physical damage. Replace piston if there is
evidence of scratches, pitting or physical damage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5823
ASSEMBLY
CAUTION: Excessive vise pressure will cause bore distortion and binding of piston.
1. Clamp caliper in a vise (with protective caps installed on jaws of vise).
Installing New Piston Seal In Caliper
2. Dip new piston seal in clean brake fluid and install in the groove of the caliper bore. Seal should
be positioned at one area in groove and gently
worked around the groove, using only your fingers until properly seated. NEVER USE AN OLD
PISTON SEAL. Be sure that fingers are clean and seal is not twisted or rolled.
3. Coat new piston boot with clean brake fluid leaving a generous amount inside boot. 4. Position
dust boot over piston after coating with brake fluid.
CAUTION: Force must be applied to the piston uniformly to avoid cocking and binding of the piston
in the bore of the caliper.
Installing Piston Into Caliper Bore
5. Install piston into caliper bore pushing it past the piston seal until it bottoms in the caliper bore. 6.
Position dust boot into the counterbore of the caliper assembly piston bore.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5824
7. Using a hammer and Installer Piston Caliper Boot, Special Tool C-4689 and Handle, Special
Tool C-4171 or equivalents, drive boot into
counterbore of the caliper.
8. Install guide pin sleeves and bushings. 9. Install brake pads.
10. Before installing caliper assembly on vehicle, inspect brake rotor. If any conditions as described
in Checking Brake Rotor for Runout and
Thickness are present the rotor, must be replaced or refaced. If the rotor does not require any
servicing, install caliper assembly.
11. Install brake hose onto caliper using banjo bolt. Torque the brake hose to caliper assembly
banjo bolt to 33 Nm (24 ft. lbs.). New seal washers
MUST always be used when installing brake hose to caliper.
12. Bleed the brake system.
Guide Pin Bushing Service
NOTE: The double pin caliper uses a sealed for life bushing and sleeve assembly. If required this
assembly can be serviced using the following procedure.
REMOVING CALIPER GUIDE PIN BUSHINGS
1. Remove caliper from brake rotor. Hang caliper assembly on a wire hook away from the brake
rotor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5825
Removing Inner Sleeve From Bushing
2. Push out and then pull the steel sleeve from the inside of the bushing using your fingers as
shown.
Removing Bushing From Caliper
3. Using your fingers, collapse one side of the bushing. Then pull on the opposite side to remove
the bushing from the brake caliper housing.
INSTALLING CALIPER GUIDE PIN BUSHINGS
Folded Caliper Guide Pin Bushing
1. Fold the bushing in half lengthwise at the solid middle section of the bushing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5826
Installing Caliper Guide Pin Bushing
2. Insert the folded bushing into the caliper housing. Do not use a sharp object to perform this step
due to possible damage to the bushing.
Bushing Correctly Installed In Caliper
3. Unfold the bushing using your fingers or a wooden dowel until the bushing is fully seated into the
caliper housing. Flanges should be seated evenly
on both sides of the bushing hole.
4. Lubricate the inside surfaces of the bushing using Mopar, Silicone Dielectric Compound or an
equivalent.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5827
Fig 7 Installing Caliper Sleeves
5. Install guide pin sleeve into one end of bushing until seal area of bushing is past seal groove in
sleeve. 6. Holding convoluted boot end of bushing with one hand, push steel sleeve bushing
through boot until one end of bushing is fully seated into seal
groove on one end of sleeve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Caliper > Component
Information > Service and Repair > Removal and Installation > Page 5828
Fig 8 Installed Caliper Bushing Sleeve
7. Holding sleeve in place, work other end of bushing over end of sleeve and into the seal grove on
sleeve. Be sure other end of bushing did not come
out of seal grove in sleeve.
8. When the sleeve is seated properly into the bushing, the sealed for life sleeve/bushing can be
held between your fingers and easily slid back and
forth without the bushing unseating from the sleeve groove.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications
Brake Fluid: Specifications
BRAKE FLUID
Specification ........................................................................................................................................
.................................................................. DOT 3
Standard ..............................................................................................................................................
........................................................... SAE J1703
NOTE: The brake fluid used in this vehicle must conform to DOT 3 specifications and SAE J1703
standards. No other type of brake fluid is recommended or approved for usage in the vehicle brake
system. Use only Mopar brake fluid or an equivalent from a tightly sealed container.
CAUTION: Never use reclaimed brake fluid or fluid from a container which has been left open. An
open container of brake fluid will absorb moisture from the air and contaminate the fluid.
CAUTION: Never use any type of a petroleum based fluid in the brake hydraulic system. Use of
such type fluids will result in seal damage of the vehicle brake hydraulic system causing a failure of
the vehicle brake system. Petroleum based fluids would be items such as engine oil, transmission
fluid, power steering fluid, etc.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 5832
Brake Fluid: Testing and Inspection
CAUTION:
The hydraulic fluid used in automotive brake systems is hygroscopic. This means that the hydraulic
fluid tends to absorb moisture from the atmosphere over periods of time. As hydraulic brake fluid
absorbs moisture, it effects the function of the vehicles hydraulic brake system. For this reason, the
vehicle's hydraulic brake fluid should be drained and replaced using fresh clean hydraulic brake
fluid every two years. When replacing hydraulic brake fluid, use only Mopar brake fluid or an
equivalent from a sealed container. Brake fluid must conform to DOT 3 specifications.
BRAKE FLUID CONTAMINATION
Indications of fluid contamination are swollen or deteriorated rubber parts. Swelling indicates the
presence of petroleum in the brake fluid.
To test for contamination, put a small amount of drained brake fluid in clear glass jar. If the fluid
separates into layers, there is mineral oil or other fluid contamination of the brake fluid.
If the brake fluid is contaminated, drain and thoroughly flush the brake system. Replace all the
rubber parts or components containing rubber coming into contact with the brake fluid. This
includes the master cylinder, proportioning valves, caliper seals, wheel cylinder seals, ABS
hydraulic control unit (HCU), and all hydraulic fluid hoses.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid > Component
Information > Specifications > Page 5833
Brake Fluid: Service and Repair
FLUID LEVEL CHECK
Check master cylinder reservoir fluid level a minimum of twice annually.
Master Cylinder Fluid Level Marks
Master cylinder reservoirs are marked with the words FULL and ADD to indicate proper brake fluid
fill level of the master cylinder.
If necessary, add brake fluid to bring the level to the bottom of the FULL mark on the side of the
master cylinder fluid reservoir. When filling master cylinder fluid reservoir do not fill the filler neck of
the fluid reservoir with brake fluid.
Use only Mopar brake fluid or an equivalent from a sealed container. Brake fluid must conform to
DOT 3, specifications.
DO NOT use brake fluid with a lower boiling point, as brake failure could result during prolonged
hard braking.
Use only brake fluid that was stored in a tightly sealed container.
DO NOT use petroleum-based fluid because seal damage will result. Petroleum based fluids would
be items such as engine oil, transmission fluid, power steering fluid ect.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Accumulator >
Component Information > Description and Operation
Brake Fluid Accumulator: Description and Operation
HCU BRAKE FLUID ACCUMULATORS AND NOISE DAMPING CHAMBER
There are two brake fluid accumulators in the Hydraulic Control Unit (HCU). There is one brake
fluid accumulator for the primary and secondary hydraulic circuits. The brake fluid accumulators
temporarily store brake fluid that is decayed from the wheel brakes during an ABS cycle. This
stored brake fluid is then used by the pump in the HCU to provide build pressure for the brake
hydraulic system.
Additionally on vehicles that are equipped with only ABS (non-traction control vehicles) there is a
mini brake fluid accumulator on the secondary hydraulic circuit which protects the master cylinder's
seals during an ABS stop. There is also a noise damping chamber on the primary hydraulic circuit.
On ABS equipped vehicles with traction control, in addition to the brake fluid accumulators there
are also two noise damping chambers in the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Description and Operation
Brake Fluid Level Sensor/Switch: Description and Operation
A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low
fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp
circuit. This switch does not disable the ABS system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Fluid Level Sensor/Switch >
Component Information > Description and Operation > Page 5840
Brake Fluid Level Sensor/Switch: Service and Repair
The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for
replacement of the brake fluid level sensor.
Fluid Level Sensor Electrical Connection
1. Remove wiring harness connector from brake fluid reservoir level sensor.
Master Cylinder Brake Fluid Level Sensor
2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With
retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master
cylinder brake fluid reservoir. 4. Insert the replacement brake fluid level sensor into brake fluid
reservoir. Be sure sensor is pushed in until retaining tabs lock it to the brake fluid
reservoir.
5. Connect the vehicle wiring harness connector to the brake fluid level sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications
Brake Hose/Line: Specifications
To Caliper Banjo Bolt ...........................................................................................................................
................................................... 48 Nm (35 ft. lbs.) Intermediate Bracket ..........................................
................................................................................................................................. 12 Nm (105 inch
lbs.) Tube Nuts To Fittings And Components
............................................................................................................................................. 17 Nm
(145 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 5844
Brake Hose/Line: Description and Operation
The purpose of the chassis brake tubes and flex hoses is to transfer the pressurized brake fluid
developed by the master cylinder to the wheel brakes of the vehicle. The chassis tubes are steel
with a corrosion resistant coating applied to the external surfaces and the flex hoses are made of
reinforced rubber. The rubber flex hoses allow for the movement of the vehicle's suspension.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Specifications > Page 5845
Brake Hose/Line: Testing and Inspection
Flexible rubber hose is used at both front brakes and at the rear axle. Inspection of brake hoses
should be performed whenever the brake system is serviced and every 7,500 miles or 12 months,
whichever comes first (every engine oil change). Inspect hydraulic brake hoses for surface
cracking, scuffing, or worn spots. If the fabric casing of the rubber hose becomes exposed due to
cracks or abrasions in the rubber hose cover, the hose should be replaced immediately. Eventual
deterioration of the hose can take place with possible burst failure. Faulty installation can cause
twisting, resulting in wheel, tire, or chassis interference.
The steel brake tubing should be inspected periodically for evidence of physical damage or contact
with moving or hot components.
The flexible brake tube sections used on this vehicle in the primary and secondary tubes from the
master cylinder to the ABS hydraulic control unit connections and the chassis brake tubes between
the hydraulic control unit and the proportioning valve must also be inspected. This flexible tubing
must be inspected for kinks, fraying and its contact with other components of the vehicle or contact
with the body of the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring
Brake Hose/Line: Service and Repair Brake Tubing Repair/Tube Flaring
General Information
CAUTION: When repairing brake chassis lines or flex hoses, the correct fasteners must be used to
attach the routing clips or hoses to the front suspension cradle. The fasteners used to attach
components to the front suspension cradle have an anti-corrosion coating due to the suspension
cradle being made of aluminum. Only Mopar replacement fasteners with the required anti-corrosion
coating are to be used if a replacement fastener is required when installing a brake chassis line or
flex hose.
Only double wall 4.75 mm (3/16 inch) steel tubing with Al-rich/ZW-AC alloy coating and the correct
tube nuts are to be used for replacement of a hydraulic brake tube.
NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes
between the master cylinder and the hydraulic control unit are 6 mm (15/64 inch). These tubes are
also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same
anti-corrosion coating. Be sure the correct tube nuts are used for the replacement of these
hydraulic brake tubes.
Care should be taken when repairing brake tubing, to be sure the proper bending and flaring tools
and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving
components or into hot areas. All tubes should be properly attached with recommended retaining
clips.
If the primary or secondary brake line from the master cylinder to the ABS Hydraulic Control Unit,
or the flexible brake lines between the hydraulic control unit and the proportioning valve require
replacement only the original factory brake lines containing a flexible section can be used. This is
required due to the movement of the front suspension cradle while the vehicle is in motion.
Cutting And Flaring Of Brake Fluid Tubing
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5848
Tube End Properly Prepared For Flaring
Using Tubing Cutter, Special Tool C-3478-A or equivalent, cut off damaged seat or tubing. Ream
out any burrs or rough edges showing on inside of tubing. This will make the ends of tubing square
and ensure better seating of flared end tubing. PLACE TUBE NUT ON TUBING BEFORE
FLARING THE TUBING.
Double Inverted Tubing Flares
Inverted Flare And ISO Flare
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5849
Inverted Double Wall Flare And ISO Flare Tubing Connections
To make a double inverted tubing flare. Open handles of Flaring Tool, Special Tool C-4047 or
equivalent. Then rotate jaws of tool until the mating jaws of tubing size are centered between
vertical posts on tool. Slowly close handles with tubing inserted in jaws but do not apply heavy
pressure to handle as this will lock tubing in place.
Place gauge (Form A) on edge over end of brake tubing. Push tubing through jaws until end of
tubing contacts the recessed notch in gauge matching the tubing size. Squeeze handles of flaring
tool and lock tubing in place. Place 3/16 inch plug of gauge (A) down in end of tubing. Swing
compression disc over gauge and center tapered flaring screw in recess of disc. Screw in until plug
gauge has seated on jaws of flaring tool. This action has started to invert the extended end of the
tubing. Remove gauge and continue to screw down until tool is firmly seated in tubing. Remove
tubing from flaring tool and inspect seat. Refer to tube routing diagrams for proper brake tube
routing and clip locations. Replace any damaged tube routing clips.
ISO Tubing Flares
Inverted Flare And ISO Flare
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5850
Inverted Double Wall Flare And ISO Flare Tubing Connections
CAUTION: All ISO style tubing flares are of metric dimensions. When performing any service
procedures on vehicles using ISO style tubing flares, metric size tubing of 4.75 mm MUST be used
with metric ISO tube flaring equipment.
To create a (metric) ISO style tubing flare, Use Snap-On Flaring Tool TFM-428, or equivalent. See
image and proceed with the steps listed below. Be sure to place the tubing nut on the tube before
flaring the tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5851
Tube End Properly Prepared For Flaring
1. Carefully prepare the end of the tubing to be flared. Be sure the end of the tubing to be flared is
square and all burrs on the inside of the tubing are
removed. This preparation is essential to obtain the correct form of a (metric) ISO tubing flare.
2. Open jaws of the Flaring Tool. Align the mating size jaws of the flaring tool around the Size of
the tubing to be flared. Close the jaws of the
Flaring Tool around the tubing to keep it from sliding out of the flaring tool, but do not lock the
tubing in place.
3. Position the tubing in the jaws of the Flaring Tool so that it is flush with the top surface of the
flaring tool bar assembly. 4. Install the correct size adaptor for the brake tubing being flared, on the
feed screw of the yoke assembly. Center the yoke and adapter over the end
of the tubing. Apply lubricant to the adapter area that contacts brake tubing. Making sure the
adapter pilot is fully inserted in the end of the brake tubing. Screw in the feed screw of the yoke
assembly until the adaptor has seated squarely on the surface of the bar assembly. This process
has created the (metric) ISO tubing flare.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Hose/Line > Component
Information > Service and Repair > Brake Tubing Repair/Tube Flaring > Page 5852
Brake Hose/Line: Service and Repair Brake Tubing/Hose Replacement
CAUTION: When installing brake chassis lines or flex hoses on the vehicle, the correct fasteners
must be used to attach the routing clips or hoses to the front suspension cradle. The fasteners
used to attach components to the front suspension cradle have an anti-corrosion coating due to the
suspension cradle being made of aluminum. Only Mopar replacement fasteners with the required
anti-corrosion coating are to be used if a replacement fastener is required when installing a brake
chassis line or flex hose.
Only double wall 4.75mm (3/16 inch) steel tubing with Al-rich/ZW-AC alloy coating and the correct
tube nuts are to be used for replacement of a hydraulic brake tube.
NOTE: On vehicles equipped with traction control, the primary and secondary hydraulic tubes
between the master cylinder and the hydraulic control unit are 6 mm (15/64 inch). These tubes are
also coated with the Al-rich/ZW-AC alloy and must be replaced with tubes having the same
anti-corrosion coating. Be sure that the correct tube nuts are used for the replacement of these
hydraulic brake tubes.
Care should be taken when replacing brake tubing, to be sure the proper bending and flaring tools
and procedures are used, to avoid kinking. Do not route the tubes against sharp edges, moving
components or into hot areas. All tubes should be properly attached with recommended retaining
clips.
If the primary or secondary brake tube from the master cylinder to the ABS Hydraulic Control Unit
(HCU) or the brake tubes from the HCU to the proportioning valve require replacement, only the
original factory brake line containing the flexible section can be used as the replacement part. This
is required due to cradle movement while the vehicle is in motion.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications > With Antilock Brakes
Brake Proportioning/Combination Valve: Specifications With Antilock Brakes
FIXED PROPORTIONING VALVE:
To Frame Rail Attaching Bolts
........................................................................................................................................................ 14
Nm (125 inch lbs.)
HEIGHT SENSING PROPORTIONING VALVE:
To Mounting Bracket Attaching Bolts
............................................................................................................................................ 23 Nm
(200 inch lbs.) Actuator Assembly Adjustment Nut
.................................................................................................................................................... 5 Nm
(45 inch lbs.) Mounting Bracket To Frame Rail Bolts
.......................................................................................................................................... 17 Nm (150
inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Specifications > With Antilock Brakes > Page 5857
Brake Proportioning/Combination Valve: Specifications Without Antilock Brakes
FIXED PROPORTIONING VALVE:
To Frame Rail Attaching Bolts
........................................................................................................................................................ 14
Nm (125 inch lbs.)
HEIGHT SENSING PROPORTIONING VALVE:
To Mounting Bracket Attaching Bolts
............................................................................................................................................ 23 Nm
(200 inch lbs.) Actuator Assembly Adjustment Nut
.................................................................................................................................................... 5 Nm
(45 inch lbs.) Mounting Bracket To Frame Rail Bolts
.......................................................................................................................................... 17 Nm (150
inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Fixed Proportioning Valve
Brake Proportioning/Combination Valve: Description and Operation Fixed Proportioning Valve
DESCRIPTION
The hydraulic brake system on all vehicles is diagonally split. This means that the left front and
right rear brakes are on one hydraulic circuit with the right front and left rear brakes on the other
hydraulic circuit.
On vehicles equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is
mounted to the front suspension crossmember on the driver's side of the vehicle. The HCU acts as
the hydraulic system junction block, diagonally splitting the brakes hydraulic system.
Fixed Proportioning Valve Location
All vehicles equipped with ABS brakes use 2 fixed proportioning valves. The fixed proportioning
valves are mounted in a common bracket on the left frame rail at the rear of the vehicle.
OPERATION
The fixed proportioning valve is made out, of aluminum and has an integral mounting bracket. The
fixed proportioning valve is non-serviceable component and must be replaced as an assembly if
found to be functioning improperly.
The fixed proportioning valve is mounted to the bottom of the left rear frame rail, just forward of the
rear shock absorber to frame rail mounting location. The proportioning valve has 2 inlet ports for
brake fluid coming from the ABS modulator, and 2 outlet ports for brake fluid going to the rear
wheel brakes.
The fixed proportioning valve operates by allowing full hydraulic pressure to the rear brakes up to a
set point, called the valve's split point. Beyond this split point the proportioning valve reduces the
amount of hydraulic pressure to the rear brakes according to a certain ratio.
Thus, on light brake pedal applications the proportioning valve allows approximately equal brake
hydraulic pressure to be supplied to both the front and rear brakes. On heavier brake pedal
applications though, the proportioning valve will control hydraulic pressure to the rear brakes, so
that hydraulic pressure at the rear brakes will be lower than that at the front brakes. This controlled
hydraulic pressure to the rear brakes prevents excessive rear wheel ABS cycling during moderate
stops.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Fixed Proportioning Valve > Page 5860
Brake Proportioning/Combination Valve: Description and Operation Proportioning Valve
Proportioning Valve Mounting Location
One assembly containing two proportioning valves are used in the system, one for each rear brake
hydraulic circuit. The proportioning valve is located on the frame rail next to the fuel tank, forward of
the right rear shock absorber. Be sure replacement proportioning valve assemblies have the same
split point and slope as the proportioning valve being replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Page 5861
Brake Proportioning/Combination Valve: Testing and Inspection
On a vehicle equipped with ABS, premature or excessive rear wheel ABS cycling may be an
indication that the brake fluid pressure to the rear brakes is above the desired output.
Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also,
ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify
that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment
Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining
material specification. The vehicles brake system is not balanced for after market brake shoe
assembly lining material.
If brake shoe assembly lining material is of satisfactory condition, and of the correct material
specification, check for proper proportioning valve function using the following procedure.
Rear Brake Proportioning Valve And Brake Tube Locations
1. Road test vehicle to be sure the vehicle is truly exhibiting a condition of excessive rear wheel
ABS cycling. Since ABS cycles both rear brakes
together both proportioning valves of the assembly must be tested. Use the following procedure to
test the proportioning valve.
2. Remove one of the chassis brake lines coming from the ABS modulator, at 3. the proportioning
valve assembly. Remove the hydraulic brake line going to one of the rear wheels of the vehicle
from the proportioning valve. 4. Remove the 2 bolts attaching the proportioning valve to the frame
rail.
CAUTION: When lowering the proportioning valve, care must be taken not to kink any of the
chassis brake lines.
5. Carefully lower the proportioning valve for clearance to install the proportioning valve test fittings.
Proportioning Valve Test Fitting Installation
6. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or equivalent into the
inlet port of the proportioning valve assembly,
from which the chassis brake line was removed. Install the removed chassis brake line into the
Pressure Test Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or
equivalent into the required outlet port of the proportioning valve. Install the required fitting from
Pressure Test Fittings, Special Tool 6833 or equivalent into the required outlet port of the
proportioning valve. Then install the removed chassis brake line into the Pressure Test Fitting.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Description and Operation > Page 5862
Pressure Gauges Installed On Pressure Test Fittings
7. Install a pressure gauge from Gauge Set, Special Tool C-4007-A or equivalent into each
pressure test fitting. Bleed air out of hose from pressure
test fittings to pressure gauges, at the pressure gauges. Then bleed air out of the brake line being
tested, at that rear wheel cylinder.
8. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000
psi) is obtained on the proportioning valve inlet
gauge. Then based on the type of brake system the vehicle is equipped with and the pressure
specification shown on the following table, compare the pressure reading on the outlet gauge to the
specification. If outlet pressure at the proportioning valve is not within specification when required
inlet pressure is obtained, replace the proportioning valve.
9. Repeat steps 2 through 7 for the other proportioning valve of the assembly.
CAUTION: When mounting the original or a replacement proportion valve on the frame rail of the
vehicle install the mounting bolts in only the two forward holes of the mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes
Brake Proportioning/Combination Valve: Service and Repair With Antilock Brakes
NOTE: The actual proportioning valves of the proportioning valve assembly are not serviceable or
replaceable. If a proportioning valve of the proportioning valve assembly is not functioning properly,
the fixed proportioning valve must be replaced as an assembly.
REMOVE
1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the proportioning valve.
2. Raise vehicle on jackstands or centered on a hoist.
CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve
and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from
entering the proportioning valve or the brake tubes.
Chassis Brake Tubes At Proportioning Valve
3. Remove the 4 chassis brake lines from the inlet and outlet ports of the proportioning valve.
Proportioning Valve Attachment To Vehicle
4. Remove the bolts attaching the proportioning valve bracket to the frame rail of the vehicle.
Remove the fixed proportioning valve assembly from
the vehicle.
INSTALL
CAUTION: When mounting the original or a replacement proportioning valve on the frame rail of
the vehicle install the mounting bolts in only the two forward holes of the mounting bracket.
1. Install proportioning valve assembly on the frame rail of the vehicle. Install the proportioning
valve assembly attaching bolts. Tighten the attaching
bolts to a torque of 14 Nm (125 inch lbs.).
2. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve
assembly. Tighten all 4 line nuts to a torque of 16 Nm
(142 inch lbs.).
3. Bleed the brake system thoroughly enough to ensure that all air has been expelled from the
hydraulic system. 4. Lower the vehicle to the ground. 5. Road test the vehicle to verify proper
operation of the vehicles brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes > Page 5865
Brake Proportioning/Combination Valve: Service and Repair Without Antilock Brakes
NOTE: The components of the proportioning valve assembly are not serviceable or replaceable. If
a component of the proportioning valve assembly is not functioning properly, the proportioning
valve must be replaced as an assembly.
REMOVE
1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the proportioning valve.
2. Raise vehicle on jackstands or centered on a hoist.
CAUTION: Before removing the brake tubes from the proportioning valve, the proportioning valve
and the brake tubes must be thoroughly cleaned. This is required to prevent contamination from
entering the proportioning valve or the brake tubes.
Chassis Brake Tubes At Proportioning Valve
3. Remove the 4 chassis brake tubes from the inlet and outlet ports of the proportioning valve.
Proportioning Valve Mounting
4. Remove the 2 bolts attaching the proportioning valve to the proportioning valve mounting
bracket. Remove the proportioning valve from the
mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Proportioning/Combination
Valve > Component Information > Service and Repair > With Antilock Brakes > Page 5866
Actuator Attachment To Proportioning Valve
5. Remove the hooked end of the proportioning valve actuator from the isolator bushing on the
lever of the height proportioning valve.
INSTALL
1. Install the hooked end of the actuator on the proportioning valve lever. Be sure isolator bushing
on lever of proportioning valve is fully seated in
hook of actuator.
NOTE: When installing height sensing proportioning valve on mounting bracket be sure
proportioning valve shield is installed between the proportioning valve and the mounting bracket.
2. Install height sensing proportioning valve on mounting bracket. Install the proportioning valve
attaching bolts. Tighten the attaching bolts to a
torque of 23 Nm (200 inch lbs.).
3. Install the 4 chassis brake lines into the inlet and outlet ports of the proportioning valve. Tighten
all 4 line nuts to a torque of 16 Nm (142 inch
lbs.).
4. Adjust the proportioning valve actuator. 5. Bleed the brake system thoroughly to ensure that all
air has been expelled from the hydraulic system. 6. Lower the vehicle to the ground. 7. Road test
the vehicle to verify proper operation of the vehicles brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications
Hydraulic Control Assembly - Antilock Brakes: Specifications
Mounting Bracket To Suspension Cradle Bolts
.................................................................................................................................. 28 Nm (250 inch
lbs.) To Mounting Bracket Isolator Attaching Bolts
..................................................................................................................................... 11 Nm (97
inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Specifications > Page 5870
Hydraulic Control Assembly - Antilock Brakes: Locations
Teves Mark 20 ICU
Hydraulic Control Unit (Integrated) Mounting Location
Located behind the steering rack on the left side of the suspension crossmember.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information
Hydraulic Control Assembly - Antilock Brakes: Description and Operation General Information
Teves Mark 20 ICU
The Hydraulic Control Unit (HCU) used with the Teves Mark 20 ABS is different from the HCU used
on previous Chrysler products with ABS. The HCU used on this ABS system is part of the
Integrated Control Unit (ICU). The HCU is part of what is referred to as the ICU because the HCU
and the Controller Antilock Brakes (CAB) are combined (integrated) into one unit. This differs from
previous Chrysler products with ABS, where the HCU and the CAB were separate components
located in different areas of the vehicle.
Teves Mark 20 ABS uses two different HCU's and CAB's depending on the type of ABS system the
vehicle is equipped with. There is a unique HCU and CAB for a vehicle equipped with just ABS and
a unique HCU and CAB for a vehicle equipped with ABS and traction control.
NOTE: The HCU and CAB used on a vehicle that is equipped with only ABS and on a vehicle that
is equipped with ABS and traction control are different. The HCU on a vehicle equipped with ABS
and traction control has a valve block housing that is approximately 1 inch longer on the low
pressure fluid accumulators side than a HCU for a vehicle that is equipped with only ABS.
ICU Mounting Location
The ICU is located on the driver's side of the vehicle, and is mounted to the front suspension
cradle. The ABS only ICU contains the following components for controlling the brake system
hydraulic pressure during ABS braking: The CAB, eight valve solenoids, (four inlet valves and four
outlet valves) fluid accumulators a pump, and an electric motor. The ABS with traction control ICU
contains the following components for controlling the brake system hydraulic pressure during ABS
braking and traction control operation: The CAB, four solenoid controlled inlet valves, four solenoid
controlled outlet valves, two hydraulic shuttle valves, two ASR valves, fluid accumulators a pump
and an electric motor. Also attached to the hydraulic control unit are the master cylinder primary
and secondary brake tubes and the brake tubes going to each wheel of the vehicle.
CAUTION: No components of the ICU are serviceable. If any component that makes up the ICU is
diagnosed as not functioning properly it MUST be replaced. The replaceable components of the
ICU, are the HCU and the CAB. The mounting bracket is also replaceable as a separate
component of the ICU. The remaining components of the ICU are not serviceable items. No
attempt should ever be made to remove or service any individual components of the HCU. This is
due to the concern of contamination entering the HCU while performing a service procedure. Also
no attempt should ever be made to remove or service any individual components of the CAB.
CAUTION: At no time when servicing the ICU should a 12 volt power source be applied to any
electrical connector of the HCU or the CAB.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 5873
Hydraulic Control Assembly - Antilock Brakes: Description and Operation System Operation
General Information The Hydraulic Control Unit (HCU) contains the valve block assembly, two
accumulators, and pump/motor assembly. Located behind the steering rack on the left side of the
suspension crossmember.
Valve Block Assembly The valve block assembly contains valves with four inlet valves and four
outlet valves. The inlet valves are spring-loaded in the open position and the outlet valves are
spring loaded in the closed position. During and antilock stop, these valves are cycled to maintain
the proper slip ratio for each wheel. If a wheel detects slip, the inlet valve is closed to prevent and
further pressure increase. Then the outlet valve is opened to release the pressure to the
accumulators until the wheel is no longer slipping. Once the wheel is no longer slipping, the outlet
valve is closed and the inlet valve is opened to reapply pressure. If the wheel is decelerating within
its predetermined limits (proper slip ratio), the inlet valve will close to hold the pressure constant.
On JX and NS Bodies which are equipped with a traction control system, there are two additional
valves that isolate the master cylinder and rear wheels. During a traction control situation the
brakes are applied to reduce wheel slippage.
Pump/Motor Assembly The pump/motor assembly provides the extra amount of fluid needed during
antilock braking. The pump is supplied fluid that is released to the accumulators when the outlet
valve is opened during and antilock stop. The pump is also used to drain the accumulator circuits
after the antilock stop is complete. The pump is operated by an integral electric motor. This
DC-type motor is controlled by the Control Antilock Brake (CAB). The CAB may turn on the pump
motor when an antilock stop is detected. The pump continues to run during the antilock stop and is
turned off after the stop is complete. Under some conditions, the pump/motor will run to drain the
accumulators during the next drive off. The pump mechanism consists of two opposing pistons
operated by an eccentric camshaft secondary hydraulic circuit. In operation, one piston craw fluid
from the accumulators. The opposing piston pumps fluid to the valve body solenoids. The CAB
monitors the pump/motor operation internally.
Accumulators The accumulators provide temporary fluid storage during an antilock stop and are
drained by the pump/motor. Each of the diagonal circuits uses a 5cc. accumulator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Description and Operation > General Information > Page 5874
Hydraulic Control Assembly - Antilock Brakes: Description and Operation Valves and Solenoids
INLET VALVES AND SOLENOIDS
There are four inlet solenoids, one for each wheel. In the released position they provide a fluid path
from the master cylinder to the wheel brakes of the vehicle. When the ABS cycle has been
completed the inlet solenoids will return to their released (open) position.
OUTLET VALVES AND SOLENOIDS
There are four outlet solenoids, one for each wheel. In the released position they are closed to
allow for normal braking. In the actuated (open) position, they provide a fluid path from the wheel
brakes of the vehicle to the hydraulic control unit HCU accumulators and pump motor. The outlet
solenoids are spring loaded in the released (closed) position during normal braking.
ASR VALVE (ABS WITH TRACTION CONTROL ONLY)
On vehicles equipped with ABS having traction control, there are two special ASR valves located in
the HCU portion of the ICU. The ASR valves are a normally open type valve and are solenoid
actuated.
The special ASR valves are used to isolate the rear (non-driven) wheels of the vehicle from the
hydraulic pressure that the HCU pump motor is sending to the front (driven) wheels, when the
traction control system is in operation. The rear brakes need to be isolated from the master cylinder
when traction control is in operation so that the HCU can build the required hydraulic pressure to
the front brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Removal
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control
Unit (HCU).
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAB 25 Way Connector
4. Remove the routing clip attaching the HCU wiring harness to the HCU mounting bracket.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
Unlocked 25 Way CAB Connector
5. Remove the 25 way connector from the Controller Antilock Brake (CAB). The 25 way connector
is removed from the CAB using the following
procedure. Grasp the lock on the 25 way connector and pull it as far out as possible. This will raise
and unlock the 25 way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake
tubes.
6. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5877
Brake Tube Connections To HCU
7. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
HCU To Suspension Cradle Mounting Bolts
8. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.
9. Remove HCU and the mounting bracket as a unit from the vehicle.
HCU Mounting Bolts
10. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the
mounting bracket. 11. Remove the CAB from the bottom of the HCU for installation on the
replacement HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5878
Hydraulic Control Assembly - Antilock Brakes: Service and Repair Installation
CAB 25 Way Connector
1. Install the Controller Antilock Brake (CAB) on the bottom of the Hydraulic Control Unit (HCU).
HCU Mounting Bolts
2. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting
bracket. Tighten the 3 mounting bolts to a torque
of 11 Nm (97 inch lbs.).
CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front
suspension crossmember.
HCU To Suspension Cradle Mounting Bolts
3. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5879
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning valve, the brake tubes must be held in proper
orientation when tightened and torqued. These tubes must not contact each other or other vehicle
components when installed. Also, after the brake tubes are installed on the HCU, ensure all spacer
clips are reinstalled on the brake tubes.
Brake Tube Connections To HCU
CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located
correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
HCU mounting bracket.
4. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
Unlocked 25 Way CAB Connector
5. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
NOTE: The CAB wiring harness must be clipped to the HCU mounting bracket. This will ensure the
wiring harness is properly routed and does not contact the brake tubes or the body of the vehicle.
6. Clip the cab wiring harness to the HCU mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic Control Assembly Antilock Brakes > Component Information > Service and Repair > Removal > Page 5880
Brake Tube Routing Clips
7. Install the routing clips on the brake tubes. 8. Lower vehicle. 9. Connect negative cable back on
negative post of the battery.
10. Bleed the base brakes and the ABS brakes hydraulic system. 11. Road test vehicle to ensure
proper operation of the base and ABS systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block >
Component Information > Specifications
Hydraulic System Junction Block: Specifications
Junction Block Mounting Bolts
...........................................................................................................................................................
28 Nm (250 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Hydraulic System Junction Block >
Component Information > Specifications > Page 5884
Hydraulic System Junction Block: Service and Repair
REMOVE
1. Using a brake pedal depressor, move and lock the brake pedal to a position past its first 1 inch
of travel. This will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the junction block.
2. Raise vehicle on jackstands or centered on a hoist.
CAUTION: Before removing the brake tubes from the junction block, the junction block and the
brake tubes must be thoroughly cleaned. This is required to prevent contamination from entering
the brake hydraulic system.
3. Remove the 6 chassis brake tubes from the junction block. 4. Remove the bolt attaching the
junction block mounting bracket to the front suspension cradle.
INSTALL
1. Install the junction block and mounting bracket on the front suspension cradle. Install the
attaching bolt and tighten to a torque of 28 Nm (250
inch lbs.).
2. Install the 6 chassis brake tubes into the inlet and outlet ports of the junction block. Tighten all 6
tube nuts to a torque of 16 Nm (145 inch lbs.). 3. Bleed the brake system thoroughly to ensure that
all air has been expelled from the hydraulic system. 4. Lower the vehicle. 5. Road test the vehicle
to verify proper operation of the vehicles brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Description and Operation
Load Compensator: Description and Operation
DESCRIPTION
CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle
are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height
sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes.
This inappropriate reduction in hydraulic pressure potentially could result in increased stopping
distance of the vehicle.
Junction Block Location
On vehicles not equipped with ABS brakes, the brake systems Hydraulic Control Unit (HCU) is
replaced by a junction block. The junction block is made of aluminum and is mounted to the front
suspension crossmember on the drivers side of the vehicle in the same location as the HCU on an
ABS equipped vehicle. The junction block is permanently attached to its mounting bracket and
must be replaced as an assembly with its mounting bracket. The junction block is used for
diagonally splitting the brake's hydraulic system.
Height Sensing Proportion Valve Operation
Vehicles not equipped with ABS brakes use a height sensing proportioning valve. The height
sensing proportioning valve is mounted on the left frame rail at the rear of the vehicle. The height
sensing proportioning valve uses an actuator assembly to attach the proportioning valve to the left
rear spring for sensing changes in vehicle height.
OPERATION
The height sensing proportioning valve regulates the hydraulic pressure to the rear brakes. The
proportioning valve regulates the pressure by sensing the load condition of the vehicle through the
movement of the proportioning valve actuator assembly. The actuator assembly is mounted
between the height sensing proportioning valve and the actuator bracket on the left rear leaf spring.
As the rear height of the vehicle changes depending on the load the vehicle is carrying the height
change is transferred to the height sensing proportioning valve. This change in vehicle height is
transferred through the movement of the left rear leaf spring. As the position of the left rear leaf
spring changes this movement is transferred through the actuator bracket to the actuator assembly
and then to the proportioning valve.
Thus, the height sensing proportioning valve allows the brake system to maintain the optimal front
to rear brake balance regardless of the vehicle load condition. Under a light load condition,
hydraulic pressure to the rear brakes is minimized. As the load condition of the vehicle increases,
so does the hydraulic pressure to the rear brakes.
The proportioning valve section of the valve operates by transmitting full input hydraulic pressure to
the rear brakes up to a certain point, called the split point. Beyond the split point the proportioning
valve reduces the amount of hydraulic pressure to the rear brakes according to a certain ratio.
Thus, on light brake applications, approximately equal hydraulic pressure will be transmitted to the
front and rear brakes. At heavier brake applications, the hydraulic pressure transmitted to the rear
brakes will be lower then the front brakes. This will prevent premature rear wheel lock-up and skid.
The height sensing section of the valve thus changes the split point of the proportioning valve
based on the rear suspension height of the vehicle When the height of the rear suspension is low,
the proportioning valve interprets this as extra load and the split point of the proportioning valve is
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Description and Operation > Page 5888
raised to allow more rear braking. When the height of the rear suspension is high, the proportioning
valve interprets this as a lightly loaded vehicle and the split point of the proportioning valve is
lowered and rear braking is reduced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Description and Operation > Page 5889
Load Compensator: Testing and Inspection
CAUTION: The use of after-market load leveling or load capacity increasing devices on this vehicle
are prohibited. Using air shock absorbers or helper springs on this vehicle will cause the height
sensing proportioning valve to inappropriately reduce the hydraulic pressure to the rear brakes.
This inappropriate reduction in hydraulic pressure potentially could result in increased stopping
distance of the vehicle.
When a premature rear wheel skid is obtained on a brake application, it may be an indication that
the hydraulic pressure to the rear brakes is above the specified output from the proportioning valve.
This condition indicates a possible malfunction of the height sensing proportioning valve, which will
require testing to verify that it is properly controlling the hydraulic pressure allowed to the rear
brakes. Premature rear wheel skid may also be caused by an incorrectly adjusted proportioning
valve actuator assembly, or contaminated front or rear brake linings.
Prior to testing a proportioning valve for function, check that all tire pressures are correct. Also,
ensure the front and rear brake linings are in satisfactory condition. It is also necessary to verify
that the brakes shoe assemblies on a vehicle being tested, are either Original Equipment
Manufacturers (OEM), or original replacement brake shoe assemblies meeting the OEM lining
material specification. The vehicles brake system is not balanced for after market brake shoe
assembly lining material.
If both front and rear brakes check OK, proceed to verify that the actuator assembly for the height
sensing proportioning valve is adjusted correctly. Refer to Adjustments. If the proportioning valve is
adjusted correctly, proceed with the test procedure for the height sensing proportioning valve as
follows:
Actuator Assembly Adjustment Nut
1. Remove the actuator assembly adjustment nut. Remove the actuator assembly from the lever on
the height sensing proportioning valve.
Brake Tube Connections To Proportioning Valve
2. Remove the chassis brake tube coming from the junction block from the front of the height
sensing proportioning valve. Remove the chassis brake
tube going to the rear brakes from the back of the height sensing proportioning valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Description and Operation > Page 5890
Proportioning Valve Test Fitting Installation
Proportioning Valve Test Fitting Installation
3. Install the required fittings from Pressure Test Fittings, Special Tool 6833 or equivalent into the
inlet port of the proportioning valve assembly,
from which the chassis brake line was removed. Install the removed chassis brake line into the
Pressure Test Fitting. Install the required fitting from Pressure Test Fittings, Special Tool 6833 or
equivalent into the required outlet port of the proportioning valve. Install the required fitting from
Pressure Test Fittings, Special Tool 6833 or equivalent into the required outlet port of the
proportioning valve. Then install the removed chassis brake line into the Pressure Test Fitting.
Pressure Gauges Installed On Pressure Test Fittings
4. Install a pressure gauge from Gauge Set, Special Tool C-4007-A or equivalent into each
pressure test fitting. Bleed air out of hose from pressure
test fittings to pressure gauges, at the pressure gauges. Then bleed air out of the brake line being
tested, at that rear wheel cylinder.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Description and Operation > Page 5891
5. With the aid of a helper, apply pressure to the brake pedal until a pressure of 6895 kPa (1000
psi) is obtained on the proportioning valve inlet
gauge. Then based on the type of brake system the vehicle is equipped with and the pressure
specification shown on the table, compare the pressure reading on the outlet gauge to the
specification. If outlet pressure at the proportioning valve is not within specification when required
inlet pressure is obtained, replace the proportioning valve.
6. Remove the pressure test fittings and pressure gauges from the proportioning valve. 7. Install
the chassis brake lines in the correct ports of the proportioning valve. 8. Install the pressure test
fittings and pressure gauges in the opposite inlet and outlet port of the height sensing proportioning
valve. Repeat steps 4
and 5 for the other proportioning valve.
9. Remove the pressure test fittings and pressure gauges from the proportioning valve.
10. Install the chassis brake lines in the correct ports of the proportioning valve. 11. Install the
actuator on the height sensing proportioning valve. Adjust the proportioning valve actuator. Refer to
Adjustments. 12. Bleed both rear hydraulic circuits at the rear brakes. 13. Road test vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Load Compensator, Rear Wheel
Brakes > Component Information > Description and Operation > Page 5892
Load Compensator: Adjustments
Proportioning valve actuator adjustment will be required if there is a complaint of premature rear
wheel lockup and the front and rear brake shoe linings checked OK during inspection, the height
sensing proportioning valve required replacement, or there is a complaint of excessive pedal effort
and the vacuum booster and brake pedal checked OK. Make sure the proportioning valve and the
mounting bracket are firmly attached to the vehicle. Then, proceed with the following procedure to
perform the adjustment of the actuator.
1. Raise vehicle. Vehicle is to be raised and supported on jackstands or with a frame contact type
hoist so the rear suspension of the vehicle is
hanging free.
2. Remove rear wheels/tires. 3. Using an appropriate jack, support the rear axle prior to the
removal of the track bar and shock absorber bolts from the rear axle. 4. Unbolt the track bar from
the rear axle. 5. Unbolt both shock absorbers from the rear axle. 6. Loosen (do not remove) both of
the leaf spring to front spring hanger pivot bolts.
NOTE: When lowering the rear axle be sure that the leaf springs do not come in contact with the
hoist limiting the downward movement of the axle. If this occurs an improper adjustment of the
actuator may result.
7. Lower the rear axle so it is at its farthest point of downward movement.
Proportioning Valve Actuator Adjustment
8. Loosen the adjustment nut on the actuator. 9. Be sure the hooked end of the actuator is correctly
(fully) seated in the clip on the proportioning valve lever and that the clip is correctly
positioned on the lever of the proportioning valve.
10. Pull the housing of the proportioning valve actuator toward the spring hanger until the lever on
the proportioning valve bottoms on the body of the
proportioning valve. Hold the proportioning valve actuator in this position while tightening the
adjustment nut to a torque of 5 Nm (45 inch lbs.). Proportioning valve adjustment is now complete.
11. Install shock absorbers and track bar on rear axle. Do not tighten the mounting bolts for any of
the loosened suspension components at this time. 12. Install the wheel/tires. 13. Lower the vehicle
to the ground. Be sure that the suspension is supporting the full weight of the vehicle. 14. Tighten
the spring to front hanger pivot bolts to a torque of 156 Nm (115 ft. lbs.). 15. Tighten the shock
absorber mounting, bolts to a torque of 101 Nm (75 ft. lbs.). 16. Tighten the track bar mounting bolt
to a torque of 95 Nm (70 ft. lbs.). 17. Road test vehicle to ensure that the premature rear wheel
lockup condition has been corrected.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > With Antilock Brakes
Brake Master Cylinder: Specifications With Antilock Brakes
DIMENSIONS:
Bore/Stroke
.................................................................................................................................................... 23.8
mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ...................................................................
................................................................................................................................. 50/50
With ABS Only: Primary Fluid Outlet Ports ..........................................................................................
........................................................................................... 7/16-24 Secondary Fluid Outlet Ports .....
..............................................................................................................................................................
.............. 7/16-24
With ABS With Traction Control: Primary Fluid Outlet Ports ...............................................................
..................................................................................................................... M12 x 1 Secondary Fluid
Outlet Ports ..........................................................................................................................................
...................................... M12 x 1
TIGHTENING TORQUES:
Mounting Nuts .....................................................................................................................................
............................................ 25 Nm (225 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Specifications > With Antilock Brakes > Page 5897
Brake Master Cylinder: Specifications Without Antilock Brakes
DIMENSIONS:
Bore/Stroke
.................................................................................................................................................... 23.8
mm x 36 mm (0.937 inch x 1.47 inch) Displacement Split ...................................................................
................................................................................................................................. 50/50 Primary
Fluid Outlet Ports .................................................................................................................................
.................................................... 7/16-24 Secondary Fluid Outlet Ports ............................................
..................................................................................................................................... 7/16-24
TIGHTENING TORQUES:
Mounting Nuts .....................................................................................................................................
............................................ 25 Nm (225 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > With Antilock Brakes
Brake Master Cylinder: Description and Operation With Antilock Brakes
Master Cylinder Assembly
The master cylinder is a standard tandem compensation port design for ABS and non ABS
systems. Traction control vehicles use a dual center port master cylinder. For proper traction
control the standard master cylinder must not be used.
A vehicle equipped with Teves Mark 20 ABS with Traction control uses a unique center port master
cylinder. If the master cylinder is replaced on a vehicle equipped with traction control be sure the
right type of master cylinder is installed.
A vehicle equipped with four wheel disc brakes (AWD applications) also have a unique master
cylinder. The master cylinder used on these vehicles have a piston bore diameter which is larger
then the master cylinder used on the other brake applications.
The primary and secondary outlet ports on the master cylinder go directly to the hydraulic control
unit HCU.
A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low
fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp
circuit. This switch does not disable the ABS system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Description and Operation > With Antilock Brakes > Page 5900
Brake Master Cylinder: Description and Operation Without Antilock Brakes
Master Cylinder Assembly
The master cylinder consists of the following components. The body of the master cylinder is an
anodized aluminum casting. It has a machined bore to accept the master cylinder piston and
threaded ports with seats for the hydraulic brake line connections. The brake fluid reservoir of the
master cylinder assembly is made of a see through polypropylene type plastic. A low fluid switch is
also part of the reservoir assembly.
This vehicle uses 3 different master cylinders. Master cylinder usage depends on what type of
brake system the vehicle is equipped with. If a vehicle is not equipped with antilock brakes, or is
equipped with antilock brakes without traction control, a conventional compensating port master
cylinder is used. If a vehicle is equipped with antilock brakes with traction control, a dual center port
master cylinder is used.
The third master cylinder used on this vehicle is unique to vehicles equipped with four wheel disc
brakes. The master cylinder used for this brake application has a different bore diameter and stroke
then the master cylinder used for the other available brake applications.
The master cylinders used on front wheel drive applications (non four wheel disc brake vehicles)
have a master cylinder piston bore diameter of 23.8 mm. The master cylinder used on the all wheel
drive applications (four wheel disc brake vehicles) have a master cylinder piston bore diameter of
25.4 mm. When replacing a master cylinder, be sure to use the correct master cylinder for the type
of brake system the vehicle is equipped with.
The master cylinder is not a repairable component and must be replaced if diagnosed to be
functioning improperly
CAUTION: Do not hone the bore of the cylinder as this will remove the anodized surface from the
bore.
The master cylinder primary outlet port supplies hydraulic pressure to the right front and left rear
brakes. The secondary outlet port supplies hydraulic pressure to the left front and right rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding
Brake Master Cylinder: Service and Repair Master Cylinder Bleeding
Bench Bleeding
CAUTION: When clamping master cylinder in vise, only clamp master cylinder by its mounting
flange, do not clamp on primary piston, seal boot or body of master cylinder.
Master Cylinder Mounted In Vise
1. Clamp the master cylinder in a vise using only the mounting flange.
NOTE: Two different size bleeding tubes are used depending on which type of master cylinder the
vehicle is equipped with. Vehicles equipped with traction control use a center port master cylinder
with a larger diameter brake tube. Vehicles not equipped with traction control use a compensating
port master cylinder using a standard 3/16 inch diameter brake tube. Be sure the correct size
bleeding tubes are used when bleeding the master cylinder.
Bleed Tubes Installed On Master Cylinder
2. Install the Bleeding Tubes, Special Tool 6920 or equivalent for a non traction control master
cylinder or Special Tool 8129 or equivalent for a
traction control master cylinder on the master cylinder. Position bleeding tubes so the outlets of
bleeding tubes will be below surface of brake fluid when reservoir is filled to its proper level.
3. Fill brake fluid reservoir with brake fluid conforming to DOT 3 specifications such as Mopar or an
Equivalent. 4. Using a wooden dowel, depress push rod slowly, and then allow pistons to return to
released position. Repeat several times until all air bubbles are
expelled from master cylinder.
5. Remove bleeding tubes from master cylinder outlet ports, and then plug outlet ports and install
fill cap on reservoir. 6. Remove master cylinder from vise. 7. Install the filler cap from the master
cylinder filler neck, on the master cylinder fluid reservoir. 8. Install the master cylinder assembly on
the power brake vacuum booster.
NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master
cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the
hydraulic system when the master cylinder was removed.
Manual Bleeding
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5903
NOTE:
- Correct manual bleeding of the brakes hydraulic system will require the aid of a helper.
- To adequately bleed the brakes using the manual bleeding procedure the rear brakes must be
correctly adjusted. Prior to the manual bleeding of the brake hydraulic system, correctly adjust the
rear brakes.
- The following wheel sequence should be used when bleeding the brake hydraulic system. The
use of this wheel sequence will ensure adequate removal of all trapped air from the brake hydraulic
system. Left Rear Wheel
- Right Front Wheel
- Right Rear Wheel
- Left Front Wheel
1. Pump the brake pedal three or four times and hold it down before the bleeder screw is opened.
2. Push the brake pedal toward the floor and hold it down. Then open the left rear bleeder screw at
least 1 full turn. When the bleeder screw opens
the brake pedal will drop all the way to the floor.
3. Release the brake pedal only after the bleeder screw is closed. 4. Repeat steps 1 through 3, four
or five times, at each bleeder screw in the required sequence. This should pass a sufficient amount
of fluid to expel
all the trapped air from the brake system. Be sure to monitor the fluid level in the master cylinder,
so it stays at a proper level so air will not enter the brake system through the master cylinder.
5. Perform a final adjustment of the rear brake shoes and then test drive vehicle to be sure brakes
are operating correctly and that pedal is solid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5904
Brake Master Cylinder: Service and Repair Master Cylinder Replacement
CAUTION: Different types of master cylinders are used on this vehicle. Vehicles equipped with
traction control use a center port master cylinder. Vehicles not equipped with traction control use a
compensating port master cylinder. Be sure to verify if the vehicle is equipped with traction control
and that the correct replacement master cylinder is used. Also, vehicles that are equipped with four
wheel disc brakes have a master with a different size piston bore than the other master cylinders. If
a new master cylinder is being installed, be sure the correct master cylinder is used for the type of
brake system the vehicle is equipped with.
REMOVE
CAUTION: Vacuum in the power brake booster must be pumped down (removed) before removing
master cylinder from power brake booster. This is necessary to prevent the power brake booster
from sucking in any contamination as the master cylinder is removed. This can be done simply by
pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is
achieved.
1. With engine not running, pump the brake pedal until a firm pedal is achieved (4 - 5 strokes).
CAUTION: Before removing the master cylinder filler tube from the brake fluid reservoir, the filler
tube, brake fluid reservoir and master cylinder must be thoroughly cleaned. This must be done to
prevent dirt particles from failing into the brake fluid reservoir and entering the brakes hydraulic
system.
2. Thoroughly clean all surfaces of the filler neck, brake fluid reservoir, and master cylinder. Use
only a solvent such as Mopar Brake Parts Cleaner
or an equivalent.
Master Cylinder Filler Tube Removal
3. Remove master cylinder filler tube from brake fluid reservoir by pushing down and rotating. Then
remove the cap from the removed filler tube and
install it on the master cylinder reservoir.
Master Cylinder Assembly
4. Remove vehicle wiring harness connector, from the brake fluid level sensor, in master cylinder
brake fluid reservoir.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5905
Primary/Secondary Brake Tubes At Master Cylinder
5. Disconnect the primary and secondary brake tubes from the master cylinder housing. Install
sealing plugs in the open brake tube outlets on master
cylinder assembly.
CAUTION: Before removing the master cylinder from the power brake vacuum booster, the master
cylinder and vacuum booster must be thoroughly cleaned. This must be done to prevent dirt
particles from failing into the power brake vacuum booster.
6. Clean the area where the master cylinder assembly attaches to the power brake booster. Use
only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Master Cylinder Mounting To Vacuum Booster
7. Remove the 2 nuts attaching the master cylinder assembly to the brake vacuum booster. 8. Slide
master cylinder assembly straight out of the power brake vacuum booster.
CAUTION: The master cylinder is used to create the seal for holding vacuum in the power brake
vacuum booster. The vacuum seal/boot on the master cylinder MUST be replaced whenever the
master cylinder is removed from the power brake vacuum booster.
9. Remove the vacuum seal located on the mounting flange of the master cylinder. The vacuum
seal is removed from the master cylinder by carefully
pulling it away from the master cylinder. Do not attempt to pry the seal off the master cylinder by
inserting a sharp tool between seal and master cylinder casting.
NOTE: It is not necessary to bleed the ABS Hydraulic Control Unit (HCU) after replacing the master
cylinder. But, the base brake hydraulic system must be bled to ensure no air is entered the
hydraulic system when the master cylinder was removed.
INSTALL
CAUTION: When replacing the master cylinder on a vehicle, a NEW vacuum seal MUST be
installed on the master cylinder. Use only procedure detailed below for installing the vacuum seal
onto the master cylinder.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5906
Vacuum Seal Installed On Master Cylinder
1. Install a NEW vacuum seal on master cylinder making sure seal sits squarely in groove of
master cylinder casting. 2. Position master cylinder on studs of power brake unit, aligning push rod
on power brake vacuum booster with master cylinder push rod. 3. Install the 2 master cylinder to
power brake unit mounting nuts. Then tighten both mounting nuts to a torque of 25 Nm (225 inch
lbs.).
CAUTION: When installing the primary and secondary brake tubes on master cylinder, be sure
brake tubes do not contact any other components within the vehicle and that there is slack in the
flexible sections of the tubes. This is required due to the movement between the ABS hydraulic
control module HCU and the master cylinder, when the vehicle is in motion.
4. Connect the primary and secondary brake tubes to master cylinder primary and secondary ports.
Brake tubes must be held securely when tightened
to control orientation of flex section. Then fully tighten the tube nuts to a torque of 17 Nm (145 inch
lbs.).
5. Install the vehicle wiring harness connector, on the brake fluid level sensor in the master cylinder
brake fluid reservoir. 6. Install filler tube into the master cylinder fluid reservoir.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5907
Brake Master Cylinder: Service and Repair Master Cylinder Reservoir Replacement
1. Clean master cylinder housing and brake fluid reservoir. Use only a solvent such as Mopar
Brake Parts Cleaner or an equivalent. 2. Remove the filler tube and brake fluid reservoir cap. Using
a syringe or equivalent type tool empty as much brake fluid as possible from the
reservoir.
CAUTION: When removing fluid reservoir from the master cylinder, do not pry off using any type of
tool. This can damage the fluid reservoir or master cylinder housing.
3. Remove the master cylinder assembly from the power brake vacuum booster.
Master Cylinder Mounted In Vise
4. Mount the master cylinder in a vise using the master cylinder mounting flange.
Fluid Reservoir Retaining Pins
5. Using correct size pin punch, remove the 2 retaining pins between the fluid reservoir and master
cylinder housing. Rock the brake fluid reservoir
from side to side while pulling up to remove it from the seal grommets in master cylinder housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5908
Master Cylinder To Fluid Reservoir Seal Grommets
6. Remove the 2 master cylinder housing to brake fluid reservoir seal grommets. 7. Install new
master cylinder housing to brake fluid reservoir sealing grommets in master cylinder housing. 8.
Lubricate reservoir mounting area with fresh clean brake fluid. Place reservoir in position over
sealing grommets. Seat reservoir into sealing
grommets using a rocking motion while firmly pressing down on fluid reservoir.
9. Be sure fluid reservoir is positioned properly on master cylinder. Bottom of fluid reservoir is to be
touching the top of both sealing grommets when
properly installed on master cylinder housing.
10. Install the 2 fluid reservoir to master cylinder retaining pins. 11. Install the master cylinder
assembly on the power brake vacuum booster. 12. Install filler tube on the fluid reservoir. Fill fluid
reservoir to its proper level as indicated on the outboard side of the fluid reservoir. Be careful not
to over fill the fluid reservoir, fluid is not intended to be stored in the filler tube. Install cap on fluid
reservoir filler tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5909
Brake Master Cylinder: Service and Repair Fluid Reservoir Fill Tube Replacement
NOTE: The master cylinder fluid reservoir filler neck is removable from the master cylinder fluid
reservoir. The filler neck if required, can be replaced as a separate component of the fluid
reservoir. The filler neck is removed and installed using the following procedure.
REMOVE
1. Check brake fluid level in master cylinder fluid reservoir to be sure brake fluid is not in the filler
neck. If brake fluid is in filler neck, lower fluid
level before removing filler neck from fluid reservoir
Master Cylinder Fluid Reservoir Filler Neck
2. Grasp filler neck at cap end and push straight down. This will cause the filler neck to pop out of
the fluid reservoir.
INSTALL
1. Wet the O-ring on the reservoir end of the filler neck with fresh clean brake fluid. 2. Position the
filler neck in the opening on the fluid reservoir. Ensure tab on filler neck is in the groove on the front
of the fluid reservoir. 3. Push down while slightly rocking filler neck until filler neck snaps into the
fluid reservoir opening. 4. Install cap on filler neck. 5. Check and/or add brake fluid in reservoir to
ensure it is at the correct level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Brake Master Cylinder >
Component Information > Service and Repair > Master Cylinder Bleeding > Page 5910
Brake Master Cylinder: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal
1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as
a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar
Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master
cylinder push rod.
Vacuum Seal Installed On Master Cylinder
4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When
installing new vacuum seal, be sure it is squarely seated
against master cylinder mounting flange and in groove of push rod.
5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6.
Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to
ensure proper operation of the vehicle's power brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications
Wheel Cylinder: Specifications
Diameter 3/4 in
To Support Plate Mounting Bolts 75 in.lb
Bleeder Screw 80 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Specifications > Page 5914
Rear Wheel Cylinder (Exploded View)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation
Wheel Cylinder: Service and Repair Wheel Cylinder Removal and Installation
REMOVE
1. In case of a leak, remove brake shoes, (replace if soaked with grease or brake fluid.)
2. Disconnect the rear brake hydraulic tube from the wheel cylinder. 3. Remove the rear wheel
cylinder attaching bolts. Then pull wheel cylinder assembly off the brake support plate.
INSTALL
1. Apply Mopar Gasket In-A-Tube or equivalent sealant around wheel cylinder mounting surface in
brake support plate. 2. Install wheel cylinder onto brake support, and tighten the wheel cylinder to
brake support plate attaching bolts to 8 Nm (75 inch lbs.). 3. Attach hydraulic brake tube to wheel
cylinder, and tighten tube to wheel cylinder fitting to 16 Nm (142 inch lbs.). 4. Install brake shoes on
support plate. 5. Install rear brake drum onto rear hub. Install rear wheel and tire assembly, tighten
wheel stud nuts to 129 Nm (95 ft. lbs.). 6. Adjust the rear brakes. 7. Bleed the entire brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5917
Wheel Cylinder: Service and Repair Cleaning and Inspection
With brake drums removed, inspect the wheel cylinder boots for evidence of a brake fluid leak.
Visually check the boots for cuts, tears, or heat cracks. If any of these conditions exist, the wheel
cylinders should be completely cleaned, inspected and new parts installed.
If a wheel cylinder is leaking and the brake lining material is saturated with brake fluid, the brake
shoes must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Hydraulic System, Brakes > Wheel Cylinder > Component
Information > Service and Repair > Wheel Cylinder Removal and Installation > Page 5918
Wheel Cylinder: Service and Repair Wheel Cylinder Overhaul
Fig 3 Wheel Cylinder
DISASSEMBLE
To disassemble the wheel cylinders, proceed as follows:
1. Pry boots away from cylinders and remove. 2. Press IN on one piston to force out opposite
piston, cup and spring. Then using a soft tool such as a dowel rod, press out the cup and piston
that
remain in the wheel cylinder.
3. Wash wheel cylinder, pistons, and spring in clean brake fluid or alcohol; (DO NOT USE ANY
PETROLEUM BASE SOLVENTS) clean
thoroughly and blow dry with compressed air. Inspect cylinder bore and piston for scoring and
pitting. (Do not use a rag as lint from the rag will stick to bore surfaces.)
4. Wheel cylinder bores and pistons that are badly scored or pitted should be replaced. Cylinder
walls that have light scratches, or show signs of
corrosion, can usually be cleaned with crocus cloth, using a circular motion. Black stains on the
cylinder walls are caused by piston cups and will not impair operation of cylinder.
ASSEMBLE
Before assembling the pistons and new cups in the wheel cylinders, dip them in clean brake fluid. If
the boots are deteriorated, cracked or do not fit tightly on the pistons or the cylinder casting, install
new boots.
1. Coat cylinder bore with clean brake fluid. 2. Lightly coat the sealing lip and outer surfaces of the
wheel cylinder cups with only Mopar Protect-A-Cup Lubricant p/n 04883068 and no
substitute.
3. Install expansion spring with cup expanders in cylinder. Install cups in each end of cylinder with
open end of cups facing each other. 4. Install piston in each end of cylinder having the flat face of
each piston contacting the flat face of each cup, already installed. 5. Install a boot over each end of
cylinder. Be careful not to damage boot during installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Actuator > Component
Information > Technical Service Bulletins > Rear Wheel Park Brake Actuator/Lever - Service
Parking Brake Actuator: Technical Service Bulletins Rear Wheel Park Brake Actuator/Lever Service
NUMBER: 05-09-99
GROUP: Brakes
DATE: Nov. 5, 1999
SUBJECT: Rear Wheel Park Brake Actuator/Lever Service
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager 1997 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH REAR WHEEL DISC BRAKES
(SALES CODE BRE OR BR3).
DISCUSSION: Whenever servicing the park brake actuator/lever of rear wheel disc brake equipped
vehicles, DO NOT attempt to repair it. The park brake actuator/lever must be replaced with p/n
04882584AA whenever service is required.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Adjustments
Parking Brake Cable: Adjustments
The park brake cables on this vehicle have an automatic self adjuster built into the park brake
pedal mechanism. When the foot operated park brake pedal is in its released (upward most)
position, a clock spring automatically adjusts the park brake cables. The park brake cables are
adjusted (tensioned) just enough to remove all the slack from the cables. The automatic adjuster
system will not over adjust the cables causing rear brake drag.
Due to the automatic adjust feature of the park brake pedal, adjustment of the parking brake cables
on these vehicles relies on proper drum brake and park brake shoe adjustment.
When the park brake pedal is applied the self adjuster is by-passed and the pedal operates
normally to engage the park brakes.
When a service procedure needs to be performed on the park brake pedal or the park brake
cables, the automatic self adjuster can be manually locked out by the service technician.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement
Parking Brake Cable: Service and Repair Front Cable Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Manually lockout the automatic self
adjusting mechanism of the park brake pedal assembly. See: Service and Repair
Park Brake Cable Attachment To Equalizer
3. Remove the intermediate and left rear park brake cable from the park brake cable equalizer.
Front Park Brake Cable Attachment To Body
4. Remove the front park cable housing retainer from body outrigger bracket. Cable is removable
by sliding a 14 mm box wrench over cable retainer
and compressing the three retaining fingers. Alternate method is to use an aircraft type hose clamp
and screwdriver.
5. Lower vehicle. 6. Remove the left front door sill molding. 7. Remove the left front kick panel for
access to the park brake cable and park brake pedal assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5929
Front Park Brake Cable At Floor Pan
8. Lift floor mat for access to park brake cable and floor pan. Pull the seal and the park brake cable
out of the floor pan of vehicle. 9. Pull park brake cable strand end forward and disconnect button
from clevis. Tap cable housing end fitting out of pedal assembly bracket.
10. Remove cable retainer from the park brake pedal assembly bracket. 11. Pull park brake cable
assembly out of vehicle through hole in floor pan.
INSTALL
1. Pass park brake cable assembly through hole in floor pan from the inside of the vehicle. 2. Pass
cable strand button through the hole in the pedal assembly bracket. 3. Install cable retainer onto
the park brake cable and then install cable retainer into pedal assembly bracket. 4. Install the end
of the park brake cable into the retainer previously installed into the park brake pedal bracket. 5.
Install cable strand button into the clevis on the park brake pedal mechanism. 6. Install the front
park brake cable floor pan seal into hole in floor pan. Seal is to be installed so the flange on the
seal is flush with the floor pan.
Fold carpeting back down on floor.
7. Raise vehicle. 8. Insert brake cable and housing into body outrigger bracket making certain that
housing retainer fingers lock the housing firmly into place. 9. Assemble the park brake cables onto
the park brake cable equalizer.
10. Release the automatic adjuster mechanism on the park brake pedal assembly. Refer to Parking
Brake Automatic Adjuster in the Service
Procedures Section in this group of the service manual for the required procedure.
11. Lower vehicle and apply the park brake pedal 1 time, this will seat the park brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5930
Parking Brake Cable: Service and Repair Intermediate Cable Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Manually lockout the automatic self
adjusting mechanism of the park brake pedal assembly. See: Service and Repair
Park Brake Cable Attachment To Equalizer
3. Remove the intermediate park brake cable from the park brake cable equalizer.
Intermediate Cable Attachment To Right Rear Cable
4. Remove the intermediate park brake cable from the cable connector attaching it to the right rear
park brake cable. 5. Remove the intermediate park brake cable from the cable guides on the frame
rails.
INSTALL
1. Install the ends of the park brake cables through the cable guides. 2. Install the intermediate
park brake cable on the cable connector at the right rear park brake cable. 3. Install the
intermediate park brake cable on the cable equalizer. 4. Remove the locking pliers from the front
park brake cable. This will activate the automatic adjuster and correctly adjust the park brake
cables. 5. Install and position the foam collar on the park brake cable to prevent it from rattling
against floor. 6. Lower vehicle and apply the park brake pedal 1 time, this will seat the park brake
cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5931
Parking Brake Cable: Service and Repair Left Rear Cable Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3.
Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake
cable.
Locking Out Automatic Adjuster
4. Create slack in rear park brake cables by locking out the automatic adjuster as described. Grasp
exposed section of front park brake cable and pull
down on it. Then install a pair of locking pliers on the cable just rearward of the second body
outrigger bracket.
Park Brake Cable Attachment To Equalizer
5. Disconnect the left rear park brake cable from the park brake cable equalizer.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5932
Park Brake Cable Removal From Body Bracket
6. To remove park brake cable housing from the body bracket, slide a 14 mm box end wrench over
retainer end compressing the three fingers.
Alternate method is to use an aircraft type hose clamp.
7. Remove the brake shoes from the brake support plate. 8. Disconnect park brake cable from park
brake actuator lever.
Removing Park Brake Cable From Brake Support Plate
9. Remove the park brake cable housing retainer from the brake support plate using a 14 mm
wrench to compress the retaining fingers.
INSTALL
1. Install the park brake cable in the brake support plate. Insert cable housing retainer into brake
support plate making certain that cable housing
retainer fingers lock the housing and retainer firmly into place.
2. Attach the park brake cable onto the park brake actuator lever. 3. Install the brake shoes on the
rear brake support plate. 4. Insert cable housing retainer into body outrigger bracket making certain
that cable housing retainer fingers lock the housing firmly into place. 5. Connect rear park brake
cable to the equalizer bracket. 6. Install brake drum, and wheel and tire assembly. 7. Remove the
locking pliers from the front park brake cable. This will automatically adjust the park brake cables.
8. Apply and release park brake pedal 1 time, this will seat the park brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5933
Parking Brake Cable: Service and Repair Right Rear Cable Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a hoist. 2. Remove rear tire and wheel assembly. 3.
Remove rear brake drum from the rear wheel of the vehicle requiring service to the rear park brake
cable.
Locking Out Automatic Adjuster
4. Create slack in the rear park brake cables by locking out the automatic adjuster as described.
Grasp exposed section of front park brake cable and
pull down on it. Then install a pair of locking pliers on the cable just rearward of the second body
outrigger bracket.
Intermediate Cable Attachment To Right Rear Cable
5. Disconnect the right rear park brake cable from the connector on the intermediate cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Cable > Component
Information > Service and Repair > Front Cable Replacement > Page 5934
Right Park Brake Cable Removal From Body Bracket
6. To remove the right park brake cable housing from the body bracket, slide a 14 mm box end
wrench over the end of cable retainer to compress the
retaining fingers. The alternate method using an aircraft type hose clamp will not work on the right
side of the vehicle.
7. Remove the brake shoes from the brake support plate. 8. Disconnect park brake cable from park
brake actuator lever.
Removing Park Brake Cable From Brake Support Plate
9. Remove the park brake cable housing retainer from the brake support plate using a 14 mm
wrench to compress the retaining fingers.
INSTALL
1. Install the park brake cable in the brake support plate. Insert cable housing retainer into brake
support plate making certain that cable housing
retainer fingers lock the housing and retainer firmly into place.
2. Attach the park brake cable onto the park brake actuator lever. 3. Install the brake shoes on the
rear brake support plate. 4. Insert cable housing retainer into body bracket making certain that
cable housing retainer fingers lock the housing firmly into place. 5. Connect the right rear park
brake cable to the connector on the intermediate park brake cable. 6. Install the brake drum, and
the wheel and tire assembly. 7. Remove the locking pliers from the front park brake cable. This will
automatically adjust the park brake cables. 8. Apply and release park brake pedal 1 time, this will
seat the park brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Specifications
Parking Brake Pedal: Specifications
TIGHTENING SPECIFICATIONS
Mounting Bolts .....................................................................................................................................
................................................ 28 Nm (21 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Specifications > Page 5938
Parking Brake Pedal: Service and Repair
REMOVE
1. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal. 2.
Remove sill scuff plate from left door sill. 3. Remove the left side kick panel. 4. Remove the
steering column cover from the lower instrument panel. 5. Remove the reinforcement from the
lower instrument panel.
Locking Out Automatic Adjuster
6. Lock out front park brake cable using the following procedure. Grasp the exposed section of the
front park brake cable and pull rearward on it.
While holding the park brake in this position, install a pair of locking pliers on the front park brake
cable just rearward of the second body outrigger bracket.
7. Remove the front park brake cable from the park brake cable equalizer. 8. Remove tension from
front park brake cable. Tension is removed by releasing the locking pliers from the front park brake
cable. 9. Remove the 3 bolts mounting the wiring junction block to the instrument panel.
NOTE: When removing the lower mounting bolt, push the park brake pedal down 5 clicks to access
the lower mounting bolt.
10. Remove the lower bolt mounting the park brake pedal to the body. 11. Remove the forward bolt
mounting the park brake pedal to the body. 12. Remove the upper bolt mounting the park brake
pedal to the body.
Park Brake Pedal Mounting
13. Disconnect the electrical connector for the brake light switch. 14. Pull downward on front park
brake cable while rotating park brake pedal mechanism out from behind junction block. 15.
Remove park brake pedal release cable from park brake mechanism. 16. Remove the ground
switch for the red brake warning lamp from the park brake pedal mechanism. 17. Remove front
park brake cable button from park brake pedal mechanism. Tap end housing of front park brake
cable out of park brake pedal
mechanism.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Pedal > Component
Information > Specifications > Page 5939
INSTALL
1. Install the ground switch for the red brake warning lamp on the park brake pedal mechanism 2.
Install park brake cable end housing into park brake pedal mechanism. 3. Install cable retainer onto
the park brake cable strand and then install retainer into pedal bracket. 4. Install cable strand
button into the clevis on the park brake pedal mechanism. 5. Install wiring harness connector on
red brake warning lamp ground switch. 6. Install the park brake release cable on the release
mechanism of the park brake pedal. 7. Position the park brake pedal mechanism into its installed
position on the body of the vehicle. 8. Remove the lock-out pin from the park brake pedal release
mechanism. 9. Loosely install the top bolt mounting the park brake pedal mechanism to the body.
10. Loosely install the forward bolt mounting the park brake pedal mechanism to the body. 11.
Loosely install the lower bolt mounting the park brake pedal mechanism to the body. 12. Tighten
pedal mechanism attaching bolts to 28 Nm (250 inch lbs.). 13. Verify that the park brake pedal is in
the fully released (full up) position. 14. Raise vehicle. 15. Install the front park brake cable on the
park brake cable equalizer. 16. Lower vehicle. 17. Remove the lock-out pin from the automatic
cable adjuster on the park brake pedal mechanism. 18. Install the electrical junction block on the
instrument panel. 19. Install the reinforcement on the lower instrument panel. 20. Install the
steering column cover on the lower instrument panel. 21. Install the left side kick panel. 22. Install
the sill scuff plate on the lower sill of the left door. 23. Install the negative (ground) cable oil the
battery. 24. Cycle the park brake pedal one time. This will seat the park brake cables and will allow
the automatic self adjuster to properly tension the park
brake cables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments
Parking Brake Shoe: Adjustments
PARK BRAKE SHOES (WITH REAR DISC BRAKES)
CAUTION: Before adjusting the park brake shoes be sure that the park brake pedal is in the fully
released position. If park brake pedal is not in the fully released position, the park brake shoes can
not be accurately adjusted.
1. Raise vehicle. 2. Remove tire and wheel.
Disc Brake Caliper
3. Remove disc brake caliper from caliper adapter. 4. Remove rotor from hub/bearing.
NOTE: When measuring the brake drum diameter, the diameter should be measured in the center
of the area in which the park brake shoes contact the surface of the brake drum.
Measuring Park Brake Drum Diameter
5. Using Gauge, Brake Shoe, Special Tool C-3919 or an equivalent, accurately measure the inside
diameter of the park brake drum portion of the
rotor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments > Page 5943
Reading Park Brake Drum Diameter
6. Using a ruler that reads in 64th of an inch, accurately read the measurement of the inside
diameter of the park brake drum from the special tool.
Setting Gauge To Park Brake Shoe Measurement
7. Reduce the inside diameter measurement of the brake drum that was taken using Special Tool
C-3919 by 1/64 of an inch. Reset Gauge, Brake
Shoe, Special Tool C-3919 or the equivalent used, so that the outside measurement jaws are set to
the reduced measurement.
Adjusting Park Brake Shoes
8. Place Gauge, Brake Shoe, Special Tool C-3919 or equivalent over the park brake shoes. The
special tool must be located straight across at the
center (widest point) of the park brake shoes.
9. Using the star wheel adjuster, adjust the park brake shoes until the lining on the park brake
shoes just touches the jaws on the special tool.
10. Install rotor on hub/bearing. 11. Rotate rotor to verify that the park brake shoes are not
dragging on the brake drum. If park brake shoes are dragging, remove rotor and back off
star wheel adjuster one notch and recheck for brake shoe drag against drum. Continue with the
previous step until brake shoes are not dragging on brake drum.
12. Install disc brake caliper on caliper adapter.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Adjustments > Page 5944
13. Install wheel and tire. 14. Tighten the wheel mounting nuts in the proper sequence until all nuts
are torqued to half the specified torque. Then repeat the tightening sequence
to the full specified torque of 129 Nm (95 ft. lbs.).
15. Lower vehicle. 16. Apply and release the park brake pedal one time. This will seat and correctly
adjust the park brake cables.
CAUTION: Before moving vehicle, pump brake pedal several times to ensure the vehicle has a firm
enough pedal to stop the vehicle.
17. Road test the vehicle to ensure proper function of the vehicle's brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal
Parking Brake Shoe: Service and Repair Removal
NOTE: On this vehicle, the park brake shoes are removed from the disc brake adapter with the disc
brake adapter removed from the vehicle.
1. Set the parking brake. The parking brake is set to keep the hub/bearing and axle shaft from
rotating when loosening the hub nut. 2. Raise vehicle. Vehicle is to be raised and supported on
jackstands or on a frame contact type hoist. 3. Remove the wheel/tire.
Cotter Pin And Nut Retainer
4. Remove the cotter pin and nut retainer from the stub shaft of the outer C/V joint.
Spring Washer
5. Remove the spring washer from the stub shaft of the outer C/V joint.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5947
Hub Nut and Washer
6. Remove the hub nut and washer from the stub shaft of the outer C/V joint. 7. Release the
parking brake.
Locking Out Automatic Adjuster
8. Create slack in the rear park brake cables by locking the out the automatic adjuster as
described. Grasp the exposed section of front park brake
cable and pull downward on it. Then install a pair of locking pliers on the front park brake cable just
rearward of the second body outrigger bracket.
Removing Caliper Guide Pin Bolts
9. Remove the disc brake caliper to adapter guide pin bolts.
Removing/Installing Caliper
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5948
10. Remove rear caliper from adapter using the following procedure. First rotate rear of caliper up
from the adapter. Then pull the front of the caliper
and the outboard brake shoe anti-rattle clip out from under the front abutment on the adapter.
Correctly Supported Caliper
11. Support caliper to prevent the weight of the caliper from damaging the flexible brake hose. 12.
Remove the rotor from the hub/bearing.
Park Brake Cable Attachment To Actuator
13. Remove the horseshoe clip from the retainer on the end of the park brake cable. 14. Remove
the end of the park brake cable from the actuator lever on the adapter.
Park Brake Cable Removal From Adapter
15. Remove the end of the park brake cable from the adapter. Park brake cable is removed from
adapter using a 1/2 wrench slipped over the park
brake cable retainer as show to compress the locking tabs on the park brake cable retainer.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5949
Speed Sensor Attaching Bolt
16. Remove the attaching bolt from the wheel speed sensor. Then remove wheel speed sensor
from hub/bearing and adapter.
Hub/Bearing Mounting Bolts
17. Remove the hub/bearing to axle mounting bolts.
Hub/Bearing Removal And Installation
18. Remove the hub/bearing from the axle and the stub shaft of the outer C/V joint. 19. Remove the
adapter from the rear axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5950
Adapter Mounted In Vise
20. Mount the adapter in a vise using the anchor boss for the park brake cable.
Lower Return Spring
21. Remove the lower return spring from the leading and trailing park brake shoes.
Leading Brake Shoe Hold Down Pin And Spring
22. Remove the hold down spring and pin from the leading park brake shoe.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5951
Brake Shoe Adjuster
23. Remove the adjuster from the leading and trailing park brake shoe.
Primary Brake Shoe Remove/Install
24. Remove the leading park brake shoe from the adapter. Leading brake shoe is removed by
rotating the bottom of the brake shoe inward until the top
of the brake shoe can be removed from the brake shoe anchor. Then remove the upper return
springs from the leading brake shoe.
Upper Return Springs
25. Remove the upper return springs from the trailing park brake shoe.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5952
Trailing Brake Shoe Hold Down Pin And Spring
26. Remove the hold down spring and pin from the trailing park brake shoe. 27. Remove the trailing
park brake shoe from the adapter. 28. Remove the park brake shoe actuator from the adapter and
inspect for signs of abnormal wear and binding at the pivot point.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5953
Parking Brake Shoe: Service and Repair Installation
1. Install the trailing brake shoe on the adapter.
NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter.
Trailing Brake Shoe Hold Down Pin And Spring
2. Install the hold down spring and pin on the trailing park brake shoe.
Upper Return Springs
3. Install the upper return springs on the trailing park brake shoe.
Primary Brake Shoe Remove/Install
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5954
4. Install the upper return springs on the leading park brake shoe. Then position the top of the
leading park brake shoe at the upper anchor and rotate
the bottom of the shoe outward until correctly installed on the adapter.
Brake Shoe Adjuster
5. Install the adjuster between the leading and trailing park brake shoe.
NOTE: When the hold down pin is installed, the long part of the hold down pin is to be positioned
strait up and down. This will ensure that the hold down pin is correctly engaged with the adapter.
Leading Brake Shoe Hold Down Pin And Spring
6. Install the hold down spring and pin on the leading park brake shoe.
Lower Return Spring
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5955
7. Install the lower return spring on the leading and trailing park brake shoes. When installing the
hold down spring it is to be installed behind the
park brake shoes.
8. Install the 4 mounting bolts for the adapter and hub/bearing into the bolt holes in the axle.
Adapter Installed On Mounting Bolts
9. Position the adapter on the 4 mounting bolts installed in the rear axle.
Hub/Bearing Removal And Installation
10. Install the hub/bearing on the stub shaft of outer C/V joint and into the end of the axle. 11. In a
progressive criss-cross pattern, tighten the 4 hub/bearing mounting bolts until the hub/bearing is
squarely seated against the axle. Then tighten
the hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.).
Speed Sensor Attaching Bolt
12. Install the wheel speed sensor on the hub/ bearing and adapter. Install the wheel speed sensor
attaching bolt. Tighten the wheel speed sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5956
attaching bolt to a torque of 12 Nm (105 inch lbs.).
13. Install the park brake cable into its mounting hole in the adapter. Be sure all the locking tabs on
the park brake cable retainer are expanded out to
ensure the cable will not pull out of the adapter.
Park Brake Cable Attachment To Actuator
14. Install the end of the park brake cable on the park brake actuator lever.
NOTE: The horseshoe clip must be installed and installed properly when the park brake cable is
installed in the adapter. The purpose of the horseshoe clip is to prevent park brake cable retainer
from moving in the adapter. If horseshoe clip is not installed the park brake cable retainer will rattle
in the adapter.
15. Install a NEW horseshoe clip on the park brake cable retainer. The horseshoe clip is installed
between the retainer for the park brake cable and the
adapter. Horseshoe clip must be installed with the curved end of the clip pointing straight up and
the edge of the curved end facing toward the rear of the vehicle.
Locking Out Automatic Adjuster
16. Remove the locking pliers from the front park brake cable. 17. Adjust the park brake
drum-in-hat brake shoes. 18. Install the rotor on the hub/bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5957
Removing/Installing Caliper
19. Carefully lower caliper and brake shoes over rotor and onto the adapter using the reverse
procedure for removal.
CAUTION: When installing guide pin bolts extreme caution should be taken not to cross-thread the
caliper guide pin bolts.
Removing Caliper Guide Pin Bolts
20. Install the caliper guide pin bolts. Tighten the guide pin bolts to a torque of 22 Nm (192 inch
lbs.).
Hub Nut and Washer
21. Clean all foreign material off the threads of the outer C/V joint stub shaft. Install the washer and
hub nut on the stub shaft of the outer C/V joint. 22. Set the parking brake. 23. Tighten the hub nut
to a torque of 244 Nm (180 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Parking Brake System > Parking Brake Shoe > Component
Information > Service and Repair > Removal > Page 5958
Spring Washer
24. Install the spring washer on the stub shaft of the outer C/V joint.
Cotter Pin And Nut Retainer
25. Install the nut retainer and cotter pin on the stub shaft of the outer C/V joint. 26. Install the
wheel and tire assembly. 27. Tighten the wheel mounting stud nuts in proper sequence until all
nuts are torqued to half specification. Then repeat the tightening sequence to the
full specified torque of 129 Nm (95 ft. lbs.).
28. Remove jackstands or lower hoist. 29. Fully apply and release the park brake pedal one time.
This will seat and correctly adjust the park brake cables.
CAUTION: Before moving vehicle, pump the brake pedal several times to insure the vehicle has a
firm brake pedal to adequately stop vehicle.
30. Road test the vehicle and make several stops to wear off any foreign material on the brakes
and to seat the brake shoe linings.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications
Vacuum Brake Booster: Specifications
DIMENSIONS:
Mounting Stud Size .............................................................................................................................
.............................................................. M8 x 1.25 Boost At 20 Inches Of Manifold Vacuum
........................................................................................................................................... 3800 Nm
(850 lbs.)
TIGHTENING TORQUES:
To Dash Panel Mounting Nuts
........................................................................................................................................................ 28
Nm (250 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Specifications > Page 5963
Vacuum Brake Booster: Description and Operation
All vehicles use a 270 mm single diaphragm power brake vacuum booster.
Power Brake Booster Identification
The power brake booster can be identified if required, by the tag attached to the body of the
booster assembly. This tag contains the following information: The production part number of the
power booster assembly, the date it was built, and who was the manufacturer of the power brake
vacuum booster.
NOTE: The power brake booster assembly is not a repairable component and must be replaced as
a complete assembly if it is found to be faulty in any way. The check valve located in the power
brake booster is not repairable but it can be replaced as an assembly separate from the power
brake booster.
The power brake booster reduces the amount of force required by the driver to obtain the
necessary hydraulic pressure to stop vehicle.
Power Brake Booster Assembly
The power brake booster is vacuum operated. The vacuum is supplied from the intake manifold on
the engine through the power brake booster check valve.
As the brake pedal is depressed, the power brake boosters input rod moves forward. This opens
and closes valves in the power booster, allowing atmospheric pressure to enter on one side of a
diaphragm- Engine vacuum is always present on the other side. This difference in pressure forces
the output rod of the power booster out against the primary piston of the master cylinder. As the
pistons in the master cylinder move forward this creates the hydraulic pressure in the brake
system.
The different engine combinations used on this vehicle require that different vacuum hose routings
to the power brake vacuum booster be used. All vacuum hoses must be routed from the engine to
the power brake vacuum booster without kinks, excessively tight bends or potential for damage to
the vacuum hose.
The power brake vacuum booster assembly mounts on the engine side of the dash panel, and is
connected to the brake pedal by the input push rod. A vacuum line connects the power booster to
the intake manifold. The master cylinder is bolted to the front of the power brake vacuum booster
assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement
Vacuum Brake Booster: Service and Repair Vacuum Booster Replacement
Removal
CAUTION: Reserve vacuum in the vacuum booster must be pumped down (removed) before
removing master cylinder from vacuum booster. This is necessary to prevent the vacuum booster
from sucking in any contamination as the master cylinder is removed. This can be done simply by
pumping the brake pedal, with the vehicle's engine not running, until a firm feeling brake pedal is
achieved.
1. With engine not running, pump the brake pedal until a firm pedal is achieved (4-5 strokes). 2.
Remove both battery cables from battery. 3. Remove the battery thermal guard and the battery
from the battery tray.
Air Inlet Resonator
4. Remove the air inlet resonator and hoses as an assembly from the throttle body and air cleaner
housing. 5. If vehicle is equipped with speed control, unplug wiring harness connector from the
speed control servo. Then disconnect vacuum lines from the
speed control servo and vacuum reservoir on battery tray.
6. Remove bolt attaching the speed control servo bracket to the battery tray Slide the bracket
forward to unhook it from the battery tray and remove.
Battery Tray Mounting Locations
7. Remove the 2 bolts and the nut attaching the battery tray to the body of the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5966
Electrical Connector At EGR Transducer
8. Remove the wiring harness connector from the EGR valve transducer.
Electrical And Vacuum Connections To Throttle Body
9. Remove wiring harness connectors from throttle position sensor and AIS motor on throttle body.
Throttle Body Attachment To Intake Manifold
10. Remove the 2 bolts attaching the throttle body to the intake manifold and the clip attaching the
wiring harness to the throttle cable bracket. Then
remove the throttle body and throttle cable bracket as an assembly from the intake manifold.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5967
Fluid Level Sensor Electrical Connection
11. Remove wiring harness connector from brake fluid level sensor in master cylinder fluid
reservoir. 12. Clean the area where the master cylinder assembly attaches to the power brake
booster. Use only a solvent such as Mopar Brake Parts Cleaner or
an equivalent.
Master Cylinder Attachment To Vacuum
13. Remove clip, attaching drain hose for wiper module to brake tube at master cylinder. Remove
drain hose from wiper module. Remove the 2 nuts,
attaching the master cylinder to the vacuum booster.
NOTE: It is not necessary to remove the brake tubes from the master cylinder when removing the
master cylinder from the vacuum booster.
14. Remove master cylinder and brake tubes as an assembly from the vacuum booster. When
master cylinder is removed, lay it out of the way on top
of the left motor mount.
EGR Valve Attachment To Intake Manifold
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5968
15. Remove the EGR Valve and the vacuum transducer as an assembly from the intake manifold.
16. Disconnect vacuum hose from check valve located on vacuum booster. DO NOT REMOVE
CHECK VALVE FROM POWER BRAKE
BOOSTER.
Vacuum Booster Input Rod Retaining Pin
17. Locate the vacuum booster input rod to brake pedal connection under the instrument panel.
Position a small screwdriver between the center tang
on the power brake booster input rod to brake pedal pin retaining clip.
18. Rotate screwdriver enough to allow retaining clip center tang to pass over end of brake pedal
pin. Then pull retaining clip off brake pedal pin.
Discard retaining clip. It is not to be reused. Replace only with a new retaining clip when
assembling.
19. Remove the 4 nuts attaching the power brake vacuum booster to the dash panel. Nuts are
accessible from under dash panel in area of the steering
column and pedal bracket assembly.
20. From outside the vehicle, slide power brake vacuum booster forward until its mounting studs
clear dash panel. Then tilt the booster up and toward
the center of vehicle to remove.
CAUTION: Do not attempt to disassemble the power brake vacuum booster it is to be serviced
ONLY as a complete assembly.
Installation
CAUTION: When installing the power brake vacuum booster in the vehicle be sure the heater
hoses do not become trapped between the booster and the dash panel of the vehicle.
1. Position vacuum booster on dash panel using the reverse procedure of its removal. 2. Install the
4 nuts mounting the vacuum booster to the dash panel. Tighten the 4 mounting nuts to a torque of
29 Nm (250 inch lbs.). 3. Using Lubriplate, or an equivalent, coat the surface of the brake pedal pin
where it contacts the vacuum booster input rod.
CAUTION: When installing the brake pedal pin on the power brake vacuum booster input rod, do
not re-use the old retaining clip.
Retaining Pin Installed On Brake Pedal Pin
4. Install vacuum booster input rod on brake pedal pin and install a NEW retaining clip. 5. Connect
the vacuum hose on the check valve in the power brake vacuum booster.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5969
EGR Valve Attachment To Intake Manifold
6. Install EGR Valve and vacuum transducer on the intake manifold. Install and tighten the 2 EGR
valve mounting bolts to a torque of 22 Nm (200
inch lbs.).
CAUTION: The master cylinder is used to create the seal for holding vacuum in the vacuum
booster. The vacuum seal on the master cylinder MUST be replaced with a NEW seal whenever
the master cylinder is removed from the vacuum booster.
CAUTION: When removing the vacuum seal from the master cylinder do not use a sharp tool.
7. Using a soft tool such as a trim stick, remove the vacuum seal from the master cylinder mounting
flange.
Vacuum Seal Installed On Master Cylinder
8. Install a NEW vacuum seal on mounting flange of the master cylinder. 9. Position master
cylinder on studs of vacuum booster, aligning push rod on vacuum booster with master cylinder
piston.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5970
Master Cylinder Attachment To Vacuum
10. Install the 2 nuts mounting the master cylinder to the vacuum booster. Tighten both mounting
nuts to a torque of 25 Nm (225 inch lbs.). 11. Install the wiper module drain hose on the wiper
module. Install the tie strap attaching the wiper module drain hose to brake tube at the master
cylinder. Tie strap should be loosely tightened so as not to collapse the wiper module drain hose.
Fluid Level Sensor Electrical Connection
12. Install the wiring harness connector on the brake fluid level sensor in the master cylinder fluid
reservoir.
Throttle Body Attachment To Intake Manifold
13. Install the throttle body and throttle cable bracket on the intake manifold. Install the 2 bolts
attaching the throttle body to the intake manifold and
tighten to a torque of 25 Nm (225 inch lbs.) Install clip attaching the wiring harness to the throttle
cable bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5971
Electrical And Vacuum Connections To Throttle Body
14. Install the wiring harness connectors on the throttle position sensor and the AIS motor on
throttle body.
Electrical Connector At EGR Transducer
15. Install the wiring harness connector on the EGR valve transducer.
Battery Tray Mounting Locations
16. Install the battery tray. Install the 2 bolts and the nut attaching the battery tray to the vehicle.
Tighten the 2 bolts and the nut to a torque of 14 Nm
(125 inch lbs.).
17. If vehicle is equipped with speed control, install the speed control servo and bracket on the
battery tray. Install and securely tighten bolt attaching
bracket to battery tray.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5972
18. If vehicle is equipped with speed control, install the wiring harness connector on the speed
control servo. Then connect the vacuum lines onto the
speed control servo and vacuum reservoir on battery tray.
Air Inlet Resonator
19. Install the air inlet resonator and hoses as an assembly on the throttle body and air cleaner
housing. Securely tighten hose clamp at air cleaner
housing and throttle body.
20. Install the battery and the battery thermal guard. 21. Install the battery cables on the battery.
22. Check the operation of the stop lamp switch and adjust if necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Power Brake Assist > Vacuum Brake Booster > Component
Information > Service and Repair > Vacuum Booster Replacement > Page 5973
Vacuum Brake Booster: Service and Repair Master Cylinder to Power Brake Booster Vacuum Seal
1. Remove the master cylinder from the power brake vacuum booster. 2. Using a soft tool such as
a trim stick, remove the vacuum seal from the master cylinder mounting flange. 3. Using Mopar
Brake Parts Cleaner or an equivalent, thoroughly clean end of master cylinder housing and master
cylinder push rod.
Vacuum Seal Installed On Master Cylinder
4. Install new master cylinder to power brake booster vacuum seal on master cylinder. When
installing new vacuum seal, be sure it is squarely seated
against master cylinder mounting flange and in groove of push rod.
5. Bleed the master cylinder assembly prior to installing it on the power brake vacuum booster. 6.
Install master cylinder assembly on the power brake vacuum booster. 7. Road test vehicle to
ensure proper operation of the vehicle's power brake system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > ABS Main
Relay > Component Information > Description and Operation
ABS Main Relay: Description and Operation
ABS FUSES
Fuse Locations In Power Distribution Center
The fuse for the ABS pump motor and the ABS system are located in the Power Distribution Center
(PDC). The PDC is located on the drivers side of the engine compartment forward of the strut
tower. The fuse for the ABS warning lamp in the instrument panel message center is located in the
junction block.
On vehicles equipped with traction control, the fuse for the traction control switch is also located in
the junction block.
The junction block is located on the left hand front cowl panel on the vehicle.
ABS RELAYS
On the Teves Mark 20 Antilock Brake System both the pump motor relay and the system relay are
located in the CAB. If either of the relays is diagnosed as not functioning properly the CAB will
need to be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications
Electronic Brake Control Module: Specifications
To HCU Mounting Bolts .......................................................................................................................
.................................................. 2 Nm (17 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 5981
Controller Antilock Brakes Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 5982
Controller Antilock Brakes Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Specifications > Page 5983
Electronic Brake Control Module: Description and Operation
The Controller Antilock Brake (CAB) is a microprocessor-based device that monitors wheel speeds
and controls the antilock functions. The CAB contains two microprocessors that receive identical
sensor signals and then independently process the information. The results are then compared to
make sure that they agree. Otherwise, the CAB will turn off the antilock and turn on the Antilock
Brake System (ABS) amber warning lamp.
The primary functions of the CAB are to:
- detect wheel locking tendencies
- control fluid pressure modulation to the brakes during antilock stop
- monitor the system for proper operation
- provide communication to the DRB while in diagnostic mode
- store diagnostic information in non-volatile memory
The CAB continuously monitors the speed of each wheel. When a wheel locking tendency is
detected, the CAB will command the appropriate valve to modulate brake fluid pressure in its
hydraulic unit. Brake pedal position is maintained during an antilock stop by being a closed system
with the use of 2 accumulators. The CAB continues to control pressure in individual hydraulic
circuits until a wheel locking tendency is no longer present. The CAB turns on the pump motor
during an antilock stop.
The antilock brake system is constantly monitored by the CAB for proper operation If the CAB
detects a system malfunction, it can disable the antilock system and turn on the ABS warning lamp.
If the antilock function is disabled, the system will revert to standard base brake system operation.
CAB Inputs Include The Following:
- ABS Warning Lamp
- Diagnostic Communication
- Four Wheel Speed Sensors
- Ignition Switch
- Fused B+
- Stop Lamp Switch
- Traction Control Switch
CAB Outputs Include The Following:
- ABS Warning Light Actuation
- Voltage
- Eight Valves
- Ten Valves With Traction Control
- Diagnostic Communication
- Body Controller Communication
- Traction Control Lamp Illumination
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Service and Repair > Removal
Electronic Brake Control Module: Service and Repair Removal
1. Disconnect the negative (ground) cable from the battery and isolate cable. 2. Using a brake
pedal depressor, move and lock the brake pedal to a position past the first inch of pedal travel. This
will prevent brake fluid from
draining out of the master cylinder when the brake tubes are removed from the Hydraulic Control
Unit (HCU).
3. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist.
CAUTION: Do not apply a 12 volt power source to any terminals of the 25 way HCU connector
when disconnected.
CAB 25 Way Connector
Unlocking CAB 25 Way Connector
4. Remove the 25 way connector from the Controller Antilock Brake (CAB) located on the bottom of
the HCU. The 25 way connector is removed
from the CAB using the following procedure. Grasp the lock on the 25 way connector and pull it as
far out as possible. This will unlock and raise the 25 way connector from the socket on the CAB.
CAUTION: Before removing the brake tubes from the HCU, the HCU must be thoroughly cleaned.
This must be done to prevent dirt particles from failing into the ports of HCU or entering the brake
tubes.
5. Thoroughly clean all surfaces of the HCU, and all brake tube nuts located on the HCU. Use only
a solvent such as Mopar Brake Parts Cleaner or
an equivalent to clean the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Service and Repair > Removal > Page 5986
Brake Tube Connections To HCU
6. Remove the brake tubes (6) from the inlet and outlet ports on the HCU.
HCU To Suspension Cradle Mounting Bolts
7. Remove the 3 bolts attaching the HCU mounting bracket to the front suspension crossmember.
8. Remove HCU and the mounting bracket as a unit from the vehicle.
HCU Mounting Bolts
9. Remove the 3 bolts mounting the HCU to the mounting bracket. Separate the HCU from the
mounting bracket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Service and Repair > Removal > Page 5987
Pump Motor To CAB Wiring Harness
10. Unplug the pump motor wiring harness from the CAB.
CAB Attaching Bolts
11. Remove the 4 bolts attaching the CAB to the valve block of the HCU.
Remove/Install CAB
12. Remove the CAB from the valve block of the HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Service and Repair > Removal > Page 5988
Electronic Brake Control Module: Service and Repair Installation
Remove/Install CAB
1. Install the Controller Antilock Brake (CAB) on the valve block of the Hydraulic Control Unit
(HCU).
CAB Attaching Bolts
2. Install the 4 bolts mounting the CAB to the valve block of the HCU. Tighten the CAB mounting
bolts to a torque of 2 Nm (17 inch lbs.).
Pump Motor To CAB Wiring Harness
3. Plug the pump/motor wiring harness into the CAB.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Service and Repair > Removal > Page 5989
HCU Mounting Bolts
4. Install the HCU on the mounting bracket. Install the 3 bolts attaching the HCU to the mounting
bracket. Tighten the 3 mounting bolts to a torque
of 11 Nm (97 inch lbs.).
CAUTION: The HCU mounting bracket to front suspension cradle mounting bolts have a unique
corrosion protection coating and a special aluminum washer. For this reason, only the original, or
original equipment Mopar replacement bolts can be used to mount the HCU bracket to the front
suspension crossmember.
HCU To Suspension Cradle Mounting Bolts
5. Install the HCU and its mounting bracket as an assembly on the front suspension crossmember.
Install the 3 bolts attaching the HCU bracket to the
crossmember. Tighten the 3 mounting bolts to a torque of 28 Nm (250 inch lbs.).
CAUTION: Because of the flexible section in the primary and secondary brake tubes, and the brake
tubes between the HCU and the proportioning valve, the brake tubes must be held in proper
orientation when tightened and torqued. These tubes must not contact each other or other vehicle
components when installed.
Brake Tube Connections To HCU
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Relays and Modules - Brakes and Traction Control > Electronic
Brake Control Module > Component Information > Service and Repair > Removal > Page 5990
CAUTION: When installing the chassis brake tubes on the HCU valve block, they must be located
correctly in the valve block to ensure proper ABS operation. Refer to image for the correct chassis
brake tube locations.
NOTE: The chassis brake tube attachment locations to the HCU, are marked on the bottom of the
HCU mounting bracket.
6. Install the 6 chassis brake tubes into their correct port locations on the HCU valve block as
shown. Tighten the tube nuts to a torque of 17 Nm
(145 inch lbs.).
NOTE: Before installing the 25 way connector in the CAB be sure the seal is properly installed in
the connector.
Unlocking CAB 25 Way Connector
7. Install the 25 way connector on the CAB using the following procedure. Position the 25 way
connector in the socket of the CAB and carefully
push it down as far as possible. When connector is fully seated by hand into the CAB socket, push
in the connector lock. This will pull the connector into the socket of the CAB and lock it in the
installed position.
Brake Tube Routing Clips
8. Install the routing clips on the brake tubes. 9. Lower vehicle.
10. Connect negative cable back on negative post of the battery. 11. Bleed the base brakes and
the ABS brakes hydraulic system. 12. Road test vehicle to ensure proper operation of the base and
ABS brake systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Description and Operation
Brake Fluid Level Sensor/Switch: Description and Operation
A fluid level switch is located in the master cylinder fluid reservoir. The switch closes when a low
fluid level is detected. The fluid level switch turns on the brake warning lamp by grounding the lamp
circuit. This switch does not disable the ABS system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Brake
Fluid Level Sensor/Switch > Component Information > Description and Operation > Page 5995
Brake Fluid Level Sensor/Switch: Service and Repair
The master cylinder or brake fluid reservoir does not have to be removed from the vehicle for
replacement of the brake fluid level sensor.
Fluid Level Sensor Electrical Connection
1. Remove wiring harness connector from brake fluid reservoir level sensor.
Master Cylinder Brake Fluid Level Sensor
2. Using fingers, compress the retaining tabs on the end of brake fluid level switch. 3. With
retaining tabs compressed, grasp opposite end of brake fluid level switch and pull it out of master
cylinder brake fluid reservoir. 4. Insert the replacement brake fluid level sensor into brake fluid
reservoir. Be sure sensor is pushed in until retaining tabs lock it to the brake fluid
reservoir.
5. Connect the vehicle wiring harness connector to the brake fluid level sensor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Harness Side > Page 6000
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 6001
Traction Control Switch: Testing and Inspection
REMOVAL AND INSTALLATION
Traction Control Switch Connector
1. Remove over steering column bezel. 2. Using an ohmmeter check for continuity reading
between pins. Refer to Switch Continuity Table.
Switch Continuity Table
Switch position - Continuity between Actuated - Pins 1 And 3 Illumination - Pins 2 And 3
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Traction
Control Switch > Component Information > Diagrams > Page 6002
Traction Control Switch: Service and Repair
Over Steering Column Bezel
REMOVAL
1. Remove the over steering column bezel. 2. Remove the two screws attaching traction control
switch to the bezel.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Electrical Specifications
Wheel Speed Sensor: Electrical Specifications
Resistance 900 - 1,300 ohms
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Specifications > Electrical Specifications > Page 6007
Wheel Speed Sensor: Mechanical Specifications
Total Indicator Run Out Allowed 0.006 in
Front Air Gap 0.014 - 0.059 in
Rear Air Gap 0.020 - 0.054 in
To Axle Or Steering Knuckle Mounting Bolt 105 in.lb
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Locations > Front Wheel Speed Sensors > Page 6010
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Front
Wheel Speed Sensor: Diagrams Front
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Front > Page 6013
Wheel Speed Sensor: Diagrams Rear
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Page 6014
Wheel Speed Sensor: Description and Operation
Front Wheel Speed Sensor
Rear Wheel Speed Sensor (FWD)
One Wheel Speed Sensor (WSS) is located at each front and rear wheel of the vehicle. The wheel
speed sensor sends a small AC signal to the Controller Antilock Brake (CAB). This signal is
generated by magnetic induction created when a toothed sensor ring (tone wheel) passes the
stationary magnetic wheel speed sensor. The CAB converts the AC signal generated at each
wheel into a digital signal. If a wheel locking tendency is detected by the CAB, it will then modulate
hydraulic pressure via the HCU to prevent the wheel(s) from locking.
The front wheel speed sensor is attached to a boss in the steering knuckle. The front tone wheel is
part of the driveshafts outboard constant velocity joint. The rear wheel speed sensor is mounted
through the rear axle, rear brake support plate and directly to the rear bearing. The rear tone wheel
on a front wheel drive vehicle is an integral part of the rear wheel hub/bearing assembly. If
damaged though, the rear tone wheel on a front wheel drive vehicle can be replaced as a individual
component of the rear hub/bearing assembly. The wheel speed sensor air gap is NOT adjustable.
The rear tone wheel on a all wheel drive vehicle, is part of the outboard constant velocity joint on
the rear driveshaft.
The four wheel speed sensors are all serviced individually, but the front tone wheel on all vehicles
and the rear tone wheel on all wheel drive vehicles are serviced as part of the front or rear
driveshaft outboard constant velocity joint.
Correct ABS system operation is dependent on accurate wheel speed signals. The vehicle's
wheels and tires must all be the same size and type to generate accurate signals. Variations in
wheel and tire size can produce inaccurate wheel speed signals, which can cause false ABS cycles
to occur.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Diagrams > Page 6015
Wheel Speed Sensor: Testing and Inspection
CAUTION: The tone wheels used on this vehicle equipped with the Teves Mark 20 Antilock Brake
System are different then those used on past models of this vehicle equipped with antilock brakes.
Reduced braking performance will result if this part is used on earlier model vehicles and an
accident could result. Do not use on pre-1998 model year vehicles.
Carefully inspect tonewheel at the suspected faulty wheel speed sensor for missing, chipped or
broken teeth, this can cause erratic speed sensor signals.
Tonewheels should show no evidence of' contact with the wheel speed sensors. If contact was
made, determine cause and correct before replacing the wheel speed sensor.
Excessive runout of the tonewheel can cause erratic wheel speed sensor signals. Replace drive
shaft assembly or rear hub/bearing assembly if tonewheel runout exceeds the specification.
Inspect tonewheels for looseness on their mounting surfaces. Tonewheels are pressed onto their
mounting surfaces and should not rotate independently from the mounting surface.
Check the wheel speed sensor head alignment to the tone wheel. Also check the gap between the
speed sensor head and the tone wheel to ensure it is at specification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement
Wheel Speed Sensor: Service and Repair Wheel Speed Sensor Replacement
Front
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
Front Speed Sensor Cable Channel Bracket
3. Remove the 2 screws attaching front channel bracket and grommet retainer to the outer frame
rail.
CAUTION: When disconnecting the wheel speed sensor from vehicle wiring harness, be careful not
to damage pins on connector
Speed Sensor Cable To Vehicle Wiring Harness
4. Pull speed sensor cable grommet and connector through the hole in the strut tower. Disconnect
speed sensor cable from vehicle wiring harness.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6018
Front Wheel Speed Sensor Attaching Bolt
5. Remove the wheel speed sensor head to steering knuckle attaching bolt. 6. Remove sensor
head from steering knuckle. If the sensor has seized, due to corrosion, DO NOT USE PLIERS ON
SENSOR HEAD. Use a
hammer and a punch and tap edge of sensor ear, rocking the sensor side to side until free.
Front Wheel Speed Sensor Cable Routing
7. Remove the wheel speed sensor cable grommets from the retaining bracket. 8. Remove front
wheel speed sensor assembly from the vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in
this section may result in contact with moving parts and/or over extension of cables, resulting in an
open circuit.
1. Connect the front wheel speed sensor cable to the vehicle wiring harness connector. Be sure
speed sensor cable connector is fully seated and
locked into vehicle wiring harness connector, then insert cable and grommet into hole in strut
tower.
CAUTION: When installing channel bracket, do not pinch the speed sensor cable under the
channel bracket.
2. Install the channel bracket and grommet retainer on the frame rail. 3. Install the 2 bolts attaching
the channel bracket to frame. Tighten the 2 attaching bolts to a torque of 11 Nm (95 inch lbs.). 4.
Insert speed sensor cable grommets into intermediate bracket on strut. Route cable from strut to
steering knuckle on the rearward side of the
stabilizer bar link.
5. Install the wheel speed sensor to steering knuckle attaching bolt. Tighten the speed sensor
attaching bolt to a torque of 12 Nm (105 inch lbs.). 6. Check the air gap between the face of the
wheel speed sensor and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
7. Install the wheel and tire assembly on vehicle. 8. Road test vehicle to ensure proper operation of
the base and ABS brake systems.
Rear
REMOVE
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the tire and
wheel assembly from the vehicle.
CAUTION: When unplugging speed sensor cable from vehicle wiring harness be careful not to
damage pins on the electrical connectors. Also inspect connectors for any signs of previous
damage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6019
Rear Speed Sensor Cable Connection To Vehicle Wiring Harness
3. Remove grommet from floor pan of vehicle and unplug speed sensor cable connector from
vehicle wiring harness.
CAUTION: When removing rear wheel speed sensor cable from routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during removal of the speed sensor cable.
Speed Sensor Cable Attachment To Brake Flex Hose
4. Carefully remove the speed sensor cable from the rear brake flex hose routing clips.
Right Rear Speed Sensor Cable Routing
5. If removing the right rear speed sensor cable, remove the speed sensor cable grommet from the
axle flange, the brake tube clip and the routing clip
from the track bar bracket on the axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6020
Rear Speed Sensor Routing Brackets And Clips
6. Remove the 2 rear wheel speed sensor cable/ brake tube routing clips. Then un-clip the speed
sensor cable from the routing clips on rear brake
tube.
CAUTION: If the speed sensor has seized, due to corrosion, do not use pliers on speed sensor
head in a attempt to remove it. Use a hammer and a punch and tap edge of sensor, rocking the
sensor from side to side until free.
Rear Wheel Speed Sensor Attaching Bolt
7. Remove the wheel speed sensor head to rear bearing attaching bolt. If sensor head does not
come loose, do not use pliers. Tap with screw driver
and hammer.
8. Remove the wheel speed sensor head from the rear bearing assembly. 9. Remove speed
sensor assembly from vehicle.
INSTALL
CAUTION: Proper installation of wheel speed sensor cables is critical to continued system
operation. Be sure that cables are installed in retainers. Failure to install cables in retainers as in
this section may result in contact with moving parts and/or over extension of cables, resulting in an
open circuit.
1. Install wheel speed sensor head. Note, the plastic anti rotation pin must be fully seated prior to
installing the attaching bolt.
CAUTION: Prior to installing the speed sensor head attaching bolt, the plastic anti-rotation pin must
be fully seated into the bearing flange.
2. Install the wheel speed sensor head to bearing Range attaching bolt. Tighten the attaching bolt
to a torque 12 Nm (105 inch lbs.). 3. Check the air gap between the face of the wheel speed sensor
and the top surface of the tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
4. Install the 2 routing brackets attaching the speed sensor cable and brake tube to the rear axle.
The rear wheel speed sensor cable should be routed
under the rear brake tube.
CAUTION: When installing rear wheel speed sensor cable in the routing clips on rear brake flex
hose, be sure not to damage the routing clips. Routing clips are molded onto the hose and will
require replacement of the brake flex hose if damaged during installation of the wheel speed
sensor cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6021
5. Install speed sensor cable into routing clips on rear brake flex hose. 6. If installing a right rear
speed sensor cable, install the speed sensor cable grommet on the axle brake flex hose bracket.
CAUTION: The wheel speed sensor cable connectors for the left and right rear wheel speed
sensors are keyed differently. Therefore, when connecting a wheel speed sensor cable to the
vehicle wiring harness, do not force the connectors together. If the connectors are forced together,
damage to the connectors will occur.
7. Plug speed sensor cable connector into vehicle wiring harness. Be sure speed sensor cable
connector is fully seated and locked into vehicle wiring
harness connector.
8. Install the speed sensor cable grommet into the body, being sure the grommet is fully seated into
the body hole. 9. Install the tire and wheel assembly on vehicle.
10. Road test vehicle to ensure proper operation of the base and ABS braking systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6022
Wheel Speed Sensor: Service and Repair Tone Wheel Replacement
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove the wheel and
tire assembly. 3. Remove rear brake drum from the hub/bearing assembly.
Rear Wheel Speed Sensor
4. Remove the rear wheel speed sensor from the rear hub/bearing flange. This will prevent damage
to the speed sensor during removal and
installation of the hub/bearing assembly.
Rear Hub/Bearing Mounting Bolts
5. Remove the 4 bolts attaching the hub/ bearing assembly to the flange of the rear axle.
Removing Rear Hub/Bearing From Axle
6. Remove the hub/bearing assembly from the rear axle and brake support plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6023
Tone Wheel Removal From Hub/Bearing Assembly
7. Install wheel lug nuts on 3 of the wheel mounting studs to protect the stud threads from damage
by the vise jaws. Mount the hub/bearing assembly
in a vise. Using Puller, Special Tool C-4693 or equivalent installed as shown remove the tone
wheel from the hub/bearing assembly.
INSTALL
Installing Tone Wheel On Hub/Bearing Assembly
1. Place hub/bearing assembly in an arbor press supported by Receiver, Special Tool, 6062A-3 or
equivalent. Position Driver, Special Tool 6908-1
or equivalent with undercut side facing up on top of the tone wheel.
Correctly Installed Tone Wheel
2. Press the tone wheel onto the hub/bearing assembly until it is flush with the end of hub shaft. 3.
Install the 4 hub/bearing to axle flange mounting bolts into the 4 mounting holes in the flange of the
rear axle. 4. Install the rear brake support plate on the 4 mounting bolts installed in the flange of the
rear axle. 5. Align the rear hub/bearing assembly with the 4 mounting bolts and start mounting bolts
into hub/ bearing assembly. Tighten the 4 bolts in a
criss-cross pattern until the hub/bearing and brake support plate is fully and squarely seated onto
flange of rear axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Brakes and Traction Control > Sensors and Switches - Brakes and Traction Control > Wheel
Speed Sensor > Component Information > Service and Repair > Wheel Speed Sensor Replacement > Page 6024
6. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 7. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
8. Check the air gap between the face of the wheel speed sensor and the top surface of the
tonewheel. Air gap must be less then the maximum
allowable tolerance of 1.2 mm (0.047 inch).
9. Install the brake drum onto the rear hub/bearing assembly.
10. Install rear wheel and tire assembly, tighten wheel stud nuts to 129 Nm (95 ft. lbs.). 11. Adjust
the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Battery Temperature
Sensor > Component Information > Description and Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch
Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6039
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Ignition Switch Lock Cylinder: > 23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page
6045
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6046
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Ignition Switch >
Ignition Switch Lock Cylinder > Component Information > Technical Service Bulletins > Page 6047
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Sensors and Switches - Starting and Charging > Neutral Safety
Switch > Component Information > Locations > Page 6051
Connector Pin Identification
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations
Starter Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6056
Engine Compartment Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Relays and Modules - Starting and Charging > Starter Relay >
Component Information > Locations > Page 6057
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Battery > Battery Temperature Sensor > Component Information >
Description and Operation
Battery Temperature Sensor: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications
Alternator: Electrical Specifications
Voltage
Powertrain Control Module (PCM) regulates charging system voltage by controlling the generator
field source (+) circuit.
The voltage range is 12.9 to 15.0 volts
Rated Amps
Nippondenso 90 A HS PN 4727220 ....................................................................................................
..................................................................... 86 amps
Nippondenso 120 A HS PN 4727221 ..................................................................................................
..................................................................... 98 amps
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Electrical Specifications > Page 6067
Alternator: Mechanical Specifications
Battery Hold Down Bolt .......................................................................................................................
................................................ 14 N.m (125 in. lbs.)
Generator Mounting Bolts ....................................................................................................................
.................................................. 54 N.m (40 ft. lbs.)
Generator B+ Terminal ........................................................................................................................
.................................................... 9 N.m (75 in. lbs.) Starter Mounting Bolts .......................................
..................................................................................................................................... 54 N.m (40 ft.
lbs.) Starter Solenoid Battery Nut ........................................................................................................
.......................................................... 10 N.m (90 in. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 6068
Alternator: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 6069
Alternator: Description and Operation
SYSTEM OPERATION
The generator is belt-driven by the engine. It is serviced only as a complete assembly. If the
generator fails for any reason, the entire assembly must be replaced.
As the energized rotor begins to rotate within the generator, the spinning magnetic field induces a
current into the windings of the stator coil. Once the generator begins producing sufficient current, it
also provides the current needed to energize the rotor.
The Y type stator winding connections deliver the induced AC current to 3 positive and 3 negative
diodes for rectification. From the diodes, rectified DC current is delivered to the vehicle electrical
system through the generator, battery, and ground terminals.
Noise emitting from the generator may be caused by: Worn, loose or defective bearings
- Loose or defective drive pulley
- Incorrect, worn, damaged or misadjusted drive belt
- Loose mounting bolts
- Misaligned drive pulley
- Defective stator or diode
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 6070
Alternator: Service and Repair
REMOVAL
1. Release hood latch and open hood.
Removal/Installation Of Battery Cables
2. Disconnect battery negative cable. 3. Remove windshield wiper housing. 4. Remove accessory
drive belt.
Generator Mounting Bracket
5. Remove bolt holding top of generator mount bracket to engine air intake plenum. 6. Remove
bolts holding outside of generator mount bracket to generator mount plate. 7. Remove bolt holding
top of generator to mount bracket. 8. Remove generator mount bracket from vehicle. 9. Rotate
generator toward rear dash panel.
Wire Connectors
10. Disconnect the push-in field wire connector from back of generator. 11. Remove nut holding B+
wire terminal to back of generator.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Alternator > Component Information >
Specifications > Page 6071
12. Separate B+ terminal from generator.
Generator Pivot Bolt
13. Remove bolt holding bottom of generator to lower pivot bracket.
Generator
14. Remove generator from vehicle.
INSTALLATION
1. Place generator in position on vehicle. 2. Install bolt to hold bottom of generator to lower pivot
bracket. 3. Place B+ terminal in position on generator. 4. Install nut to hold B+ wire terminal to back
of generator. 5. Connect the push-in field wire connector into back of generator. 6. Rotate
generator forward away from dash panel. 7. Place generator mount bracket in position on vehicle.
8. Install bolt to hold top of generator to mount bracket. 9. Install bolts to hold outside of generator
mount bracket to generator mount plate.
10. Install bolt to hold top of generator mount bracket to engine air intake plenum. 11. Install
accessory drive belt. 12. Install windshield wiper housing. 13. Connect battery negative cable. 14.
Verify generator charge rate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Charging System > Voltage Regulator > Component Information >
Description and Operation
Voltage Regulator: Description and Operation
SYSTEM OPERATION
The Electronic Voltage Regulator (EVR) is not a separate component. It is actually a Voltage
regulating circuit located within the Powertrain Control Module (PCM). The EVR is not serviced
separately. If replacement is necessary, the PCM must be replaced.
Operation: The amount of DC current produced by the generator is controlled by EVR circuitry
contained within the PCM. This circuitry is connected in series with the generators second rotor
field terminal and its ground.
Voltage is regulated by cycling the ground path to control the strength of the rotor magnetic field.
The EVR circuitry monitors system line Voltage and battery temperature (refer to Battery
Temperature Sensor for more information). It then compensates and regulates generator current
output accordingly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair
Ignition Lock: Service and Repair
This article has been updated by technical service bulletin number 19-06-99 Dated Sep. 17, 1999.
Note: This bulletin applies to vehicles equipped with an automatic transaxle.
Ignition Switch Housing Service
The ignition switch housing, p/n 04690523, is now available as a separate service part. This part
eliminates the need to replace the complete steering column assembly if the service issue only
relates to the ignition switch housing.
The service procedure to replace the ignition switch housing is below.
REMOVAL
1. Disconnect negative (ground) cable from the battery and isolate cable from battery terminal.
2. Remove the screws attaching the lower steering column cover to the instrument panel, then
remove the cover from the lower instrument panel.
3. Remove the parking brake release cable from the parking brake release lever, then move the
lower steering column cover out of the way.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 6079
4. Remove the 10 bolts attaching the lower steering column cover liner to the instrument panel,
then remove the lower steering column cover liner.
5. Remove the 3 screws attaching the upper and lower shrouds to the steering column, then
separate and remove both shrouds. 6. Remove the trim bezel on the instrument panel above the
steering column. The trim bezel is mounted to the instrument panel using 2 screws (one
on each side of the column) and retaining clips.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 6080
7. Remove the 2 screws securing the steering column fixed shroud to the steering column, then
remove the shroud.
8. Remove the two screws holding the metal cover in place below the shifter/ignition interlock
linkage, then remove the cover.
9. Disconnect the shifter/ignition interlock link from the lever on the lock cylinder housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 6081
10. Remove the key cylinder. To do this:
- Turn the key placing the key cylinder in the ON position.
- Depress and hold the retaining tab on the bottom of the lock cylinder housing.
- Pull the key cylinder straight out of the lock cylinder housing.
11. Remove the vehicle wiring harness connector from the key cylinder halo lamp. 12. Remove the
key cylinder halo lamp from the lock cylinder housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 6082
13. Remove the ignition switch mounting screw.
14. Depress the two retaining tabs, then remove the ignition switch from the lock cylinder housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 6083
15. Disconnect both tilt mechanism springs from their mounting posts on the tilt housing, then move
them to the side out of the way. 16. While supporting the lock cylinder housing, remove both
mounting screws securing the lock cylinder housing to the column. 17. Remove the lock cylinder
housing from the bottom of the steering column.
INSTALLATION
1. Install the lock cylinder housing in the bottom of the steering column lining up the mounting
holes. 2. Install the self-tapping lock cylinder housing mounting screws through the top of the
column into the housing. Tighten the two mounting screws to
a torque of 11 Nm (100 inch lbs.).
3. Connect both tilt mechanism springs back onto their mounting posts making sure the spring
hooks engage the grooves in the posts. 4. Ensure that the ignition switch and the actuator shaft in
the lock cylinder housing are in the ON position.
5. Carefully install the ignition switch over the actuator shaft. The switch will snap over the retaining
tabs on the housing. 6. Install the ignition switch mounting screw. 7. Install the key cylinder halo
lamp on the lock cylinder housing. 8. Install the vehicle wiring harness connector onto the key
cylinder halo lamp. 9. Install the key cylinder (with key in it turned to the ON position) by sliding it
straight into the lock cylinder housing aligning the retaining tab on
the key cylinder with the hole in the lock cylinder housing.
10. Turn the key to the OFF position and remove the key. 11. Connect the shifter/ignition interlock
link to the lever on the lock cylinder housing by aligning the retaining tab on the lever with the ramp
on the
link, then pushing the two together.
12. Install the metal cover in place below the shifter/ignition interlock linkage using the two screws.
CAUTION: After the completion of step 12 in the installation process, you must verify that the shift
lever interlock functions properly. With ignition
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Lock > Component Information > Service
and Repair > Page 6084
key removed from lock cylinder and brake pedal depressed, attempt to shift out of park. If the lever
moves out of the park position you must repeat steps 11 and 12 of the installation procedure.
13. Install the steering column fixed shroud on the steering column using its 2 mounting screws. 14.
Install the trim bezel on the instrument panel above the steering column. The trim bezel is mounted
to the instrument panel using 2 screws (one on
each side of the column) and retaining clips.
15. Install the lower steering column shroud on the steering column. Install and securely tighten the
center screw attaching the lower shroud to the tilt
head on the column.
16. Install the upper steering column shroud over the tilt head of the steering column snapping it
into place on the lower shroud. Install and securely
tighten the 2 remaining screws attaching the upper shroud to the lower shroud.
17. Install the steering column cover liner on the instrument panel below the steering column.
Install and securely tighten the 10 bolts attaching the
steering column cover liner to the instrument panel.
18. Install the parking brake pedal release cable on the parking brake release lever in the lower
steering column cover. 19. Install the lower steering column trim cover on the instrument panel
below the steering column.
Install and securely the screws attaching the lower steering column cover to the instrument panel.
20. Connect the negative (ground) cable on the battery terminal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 >
Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: Customer Interest Ignition Key - Will Not Turn And/Or Cannot Be
Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Customer Interest for Ignition Switch Lock Cylinder: > 23-23-00 >
Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6094
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: >
23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed
Ignition Switch Lock Cylinder: All Technical Service Bulletins Ignition Key - Will Not Turn And/Or
Cannot Be Removed
NUMBER: 23-23-00
GROUP: Body
DATE: JUNE 30, 2000
SUBJECT: Ignition Key Will Not Turn And/Or Cannot Be Removed
MODELS: 1997 - 2000 (NS) Town & Country/Caravan/Voyager
OVERVIEW: This bulletin involves performing one or any combination of the following procedures;
cutting a new ignition key, and/or adjusting transmission shifter cable, and/or replacing the ignition
lock cylinder and/or replacing the ignition lock housing and switch assembly.
SYMPTOM/CONDITION:
1. Cannot turn the ignition key when attempting to start vehicle, this condition may be intermittent.
2. Unable to remove the ignition key from the lock cylinder.
PARTS REQUIRED:
AR(1)04778115 Key
AR(1)05003843AB Cylinder, Ignition Lock
AR(1)04690523 Assembly, Ignition Switch and Lock Housing
EQUIPMENT POSSIBLY REQUIRED: Key Cutter such as Pentastar Service Equipment (PSE)
IL-MK1-P2627 or IL-ECM-100 T-27 Torx Bit T-25 Torx Bit T-10 Tamper Resistant Torx Bit
SR-706059 Lock Cylinder Build Kit, Pentastar Service Equipment (PSE)
DIAGNOSIS/REPAIR PROCEDURE:
DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL EQUIPMENT.
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLERS MOBILE SERVICE PROGRAM.
SYMPTOM/CONDITION ONE
1. Ensure the steering wheel is centered and the vehicle is positioned on a level surface.
2. Disconnect the negative battery cable.
3. Insert ignition key into the ignition lock cylinder and attempt to rotate the key to the start position
and then the accessory position.
4. If the key does not turn, remove the key from the lock cylinder and rotate it 180°. Reinsert the
key into the lock cylinder and attempt to rotate the key. If the key does not turn skip to step 14. If
the key does turn make a new key.
NOTE:
USE THE KEY CODE ON THE VEHICLE INVOICE TO CORRECTLY CUT THE NEW KEY. KEY
CODES ARE ALSO AVAILABLE USING THE D.I.A.L. SYSTEM, MAIN MENU OPTION 13. DO
NOT USE A KEY DUPLICATOR TO MAKE THE NEW KEY.
5. Insert the new ignition key into the ignition lock cylinder and attempt to rotate the key to the start
position and then the accessory position.
6. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
7. If the key turns, repeat steps 5 and 6 ten times. If the key continues to rotate smoothly the repair
is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 8.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Ignition Switch Lock Cylinder: >
23-23-00 > Jun > 00 > Ignition Key - Will Not Turn And/Or Cannot Be Removed > Page 6100
8. Remove the ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000 Town
& Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005). DO NOT
ATTEMPT TO DISASSEMBLE THE Lock CYLINDER.
9. Build a new lock cylinder to the key code on the vehicle invoice, using the instructions in the
Pentastar Service Equipment SR-706059 Lock Cylinder Build Kit.
10. Install the new ignition lock cylinder using the procedure outlined on page 8D-29 of the 2000
Town & Country, Caravan and Voyager Service Manual (Publication No. 81-370-0005).
11. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
12. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
13. If the key turns, repeat steps 11 and 12 ten times. If the key continues to rotate smoothly the
repair is complete. If the key fails to turn smoothly at each rotation attempt, continue to step 14.
14. Remove the ignition lock housing and ignition switch as an assembly using the procedure
outlined beginning on page 19-47 of the 2000 Town & Country, Caravan and Voyager Service
Manual (Publication No. 81-370-0005).
NOTE:
SKIP STEPS 13 AND 14 OF THE SERVICE MANUAL REMOVAL PROCEDURE SO THE
IGNITION LOCK HOUSING AND IGNITION SWITCH ARE REMOVED AS AN ASSEMBLY.
15. Install a new ignition lock housing and ignition switch assembly, p/n 04690523, using the
procedure outlined beginning on page 19-49 of the 2000 Town & Country, Caravan and Voyager
Service Manual (Publication No. 81-370-0005).
NOTE:
PRIOR TO PERFORMING STEP 2 OF THE SERVICE MANUAL LOCK HOUSING
INSTALLATION PROCEDURE, INSTALL THEN REMOVE THE TWO LOCK CYLINDER
HOUSING MOUNTING SCREWS INTO THE LOCK HOUSING MOUNTING HOLES TO CREATE
THE THREADS IN THE HOLES.FAILURE TO CREATE THE MOUNTING HOLE THREADS
PRIOR TO INSTALLATION TO THE STEERING COLUMN MAY CAUSE MISALIGNMENT OF
THE LOCK HOUSING TO STEERING COLUMN AND DAMAGE BINDING OF STEERING
COLUMN MAY RESULT. STEPS 5 AND 6 OF THE SERVICE MANUAL INSTALLATION
PROCEDURE FOR THE LOCK HOUSING ARE NOT NECESSARY FOR THIS TSB
PROCEDURE. WHEN PERFORMING STEP 9 OF THE SERVICE MANUAL PROCEDURE USE
THE NEW LOCK CYLINDER THAT WAS BUILT IN STEP 9 OF THE SYMPTOM/CONDITION
ONE DIAGNOSIS / REPAIR PROCEDURE OF THIS BULLETIN.
16. Insert the new ignition key into the new ignition lock cylinder and attempt to rotate the key to the
start position and then the accessory position.
17. If the key turns, remove the key from the lock cylinder and turn it over 180° and reinsert the key
into the lock cylinder. Attempt to rotate the key.
18. If the key turns, repeat steps 16 and 17 ten times. If the key continues to rotate smoothly the
repair is complete.
SYMPTOM/CONDITION TWO
1. Check the operation of the shift lever. The shift lever should fall freely away from the driver when
it is brought up into the Park position.
2. If the shift lever does not seat fully up and away from the driver the column will not allow the key
to be removed.
3. If binding of the shift lever is discovered, adjust the transmission shift cable using the procedure
outlined on page 21-114 of the 2000 Town & Country, Caravan and Voyager Service Manual
(Publication No. 81-370-0005).
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE: P8 - New Part XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Page 6101
Ignition Switch Lock Cylinder: Service and Repair
REMOVAL
1. Disconnect negative cable from battery.
Steering Column Cover
2. Remove steering column cover retaining screws.
Steering Column Shroud Screws
3. Remove screws holding steering column shrouds and remove lower shroud.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Ignition Switch > Ignition Switch Lock Cylinder >
Component Information > Technical Service Bulletins > Page 6102
Lock Cylinder Retaining Tab
4. Place key cylinder in RUN position. Depress lock cylinder retaining tab and remove key cylinder.
INSTALLATION
1. Install key in lock cylinder. Turn key to run position (retaining tab on lock cylinder can be
depressed).
Socket In Lock Cylinder Housing
2. The shaft at the end of the lock cylinder aligns with the socket in the end of the housing. To align
the socket with the lock cylinder, ensure the
socket is in the Run position.
3. Align the lock cylinder with the grooves in the housing. Slide the lock cylinder into the housing
until the tab sticks through the opening in the
housing.
4. Turn the key to the Off position. Remove the key. 5. Install lower steering column shroud. 6.
Install steering column cover. 7. Connect negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations
Transmission Range Sensor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Neutral Safety Switch > Component Information >
Locations > Page 6106
Connector Pin Identification
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications
Starter Motor: Electrical Specifications
Power rating ........................................................................................................................................
............................................................... 1.2 kilowatts Voltage ............................................................
......................................................................................................................................................... 12
Volts Free Running Test:
- Voltage ..............................................................................................................................................
............................................................. 11 Volts
- Amperage Draw ................................................................................................................................
.............................................................. 73 Amp
- Minimum Speed ................................................................................................................................
........................................................... 3,401 rpm
Solenoid closing Voltage .....................................................................................................................
.................................................................... 7.5 Volts Cranking Amperage Draw Test .......................
........................................................................................................................................... 150 to 200
Amps
NOTE: Engine should be up to operating temperature. Extremely heavy oil or tight engine will
increase starter amperage draw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Electrical Specifications > Page 6111
Starter Motor: Mechanical Specifications
Starter Mounting Bolts .........................................................................................................................
................................................... 54 N.m (40 ft. lbs.) Starter Solenoid Battery Nut .............................
...................................................................................................................................... 10 N.m (90 in.
lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6112
Starter Motor: Application and ID
No of fields = 4
No of Poles = 4
Brushes = 4
Drive = Conventional Gear Train
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6113
Starter Motor: Service and Repair
REMOVAL
1. Release hood latch and open hood.
Battery Negative Cable
2. Disconnect battery negative cable. 3. Hoist and support vehicle on safety stands.
Wire Connectors
4. Remove nut holding B+ terminal to starter solenoid. 5. Disconnect solenoid connector from
starter.
Starter Bolts
6. Remove bolts holding starter to transaxle bell- housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Motor > Component Information >
Specifications > Page 6114
Starter
7. Remove starter from bellhousing. 8. Separate starter spacer from transaxle bellhousing.
INSTALLATION
1. Place starter spacer in position on transaxle bellhousing, flange toward flywheel. 2. Place starter
in position on bellhousing. 3. Install bolts to hold starter to transaxle bellhousing. 4. Connect
solenoid connector into starter. 5. Install nut to hold B+ terminal to starter solenoid. 6. Lower
vehicle. 7. Connect battery negative cable. 8. Verify starter operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
Starter Relay: Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 6118
Engine Compartment Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Starting System > Starter Relay > Component Information > Locations
> Page 6119
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6125
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6126
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6127
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6128
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6129
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6130
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6131
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6132
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6133
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6134
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6135
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6136
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6137
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6138
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6139
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6140
Auxiliary Power Outlet: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6141
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6142
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6143
Auxiliary Power Outlet: Electrical Diagrams
Horn/Cigar Lighter/Power Outlet (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Diagram Information and Instructions > Page 6144
Horn/Cigar Lighter/Power Outlet (Part 2 Of 2)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Auxiliary Power Outlet > Component
Information > Diagrams > Page 6145
Auxiliary Power Outlet: Service and Repair
REMOVAL
Outlet Base Removal
1. Look inside and note position of the retaining bosses. 2. Using external snap ring pliers with 90
degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base.
Tool For Outlet Removal
3. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the
same. 4. Disconnect the base wires. 5. Set base aside. Remove light ring and disconnect wire.
INSTALLATION
1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring
at the same location 3. Push base into the bezel till it locks. 4. Install 12 Volt outlet cap and check
operation of outlet or element.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Locations
Diode: Locations
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Locations > Page 6149
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Locations > Page 6150
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Locations > Page 6151
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Diode > Component Information >
Locations > Page 6152
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions
Power Distribution Center: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6157
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6158
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6159
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6160
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6161
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6162
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6163
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6164
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6165
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6166
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6167
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6168
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6169
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6170
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6171
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6172
Power Distribution Center: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6173
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6174
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6175
Power Distribution Center: Connector Views
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6176
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6177
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6178
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6179
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6180
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6181
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6182
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6183
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6184
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6185
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Center <-->
[Electrical Accessory Panel] > Component Information > Diagrams > Diagram Information and Instructions > Page 6186
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center
Fuse: Locations Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6191
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6192
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6193
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6194
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6195
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6196
Fuse: Locations Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6197
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6198
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6199
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse > Component Information >
Locations > Power Distribution Center > Page 6200
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block
Fuse Block: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6205
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6206
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6207
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6208
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6209
Fuse Block: Diagrams Power Distribution Block
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6210
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6211
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6212
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6213
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Fuse Block > Component
Information > Diagrams > Junction Block > Page 6214
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions
Multiple Junction Connector: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6219
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6220
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6221
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6222
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6223
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6224
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6225
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6226
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6227
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6228
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6229
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6230
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6231
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6232
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6233
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6234
Multiple Junction Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6235
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6236
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6237
Multiple Junction Connector: Connector Views
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6238
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6239
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6240
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6241
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6242
Multiple Junction Connector: Electrical Diagrams
Junction Block
Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6243
Junction Block (Part 1 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6244
Junction Block (Part 2 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6245
Junction Block (Part 3 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6246
Junction Block (Part 4 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6247
Junction Block (Part 5 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6248
Junction Block (Part 6 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6249
Junction Block (Part 7 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6250
Junction Block (Part 8 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6251
Junction Block (Part 9 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6252
Junction Block (Part 10 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6253
Junction Block (Part 11 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6254
Junction Block (Part 12 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6255
Junction Block (Part 13 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6256
Junction Block (Part 14 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6257
Junction Block (Part 15 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 6258
Junction Block (Part 16 Of 16)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Multiple Junction Connector >
Component Information > Diagrams > Page 6259
Multiple Junction Connector: Service and Repair
Junction Block
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement.
Junction Block
3. Disconnect four, forty-way connectors from Junction Block. 4. Disconnect two wire connectors
from bottom of Body Control Module. 5. Remove bolts holding Junction Block to dash panel
mounting. 6. Remove Junction Block from mounting bracket. 7. Remove screws holding Body
Control Module to Junction Block. 8. Slide Body Control Module downward to disconnect guide
studs on Junction Block from BCM mounting bracket. 9. Separate Junction Block from Body
Control Module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Power Distribution Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Power Distribution Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Locations
Relay Box: Locations
ABS Fuses
ABS Fuses
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block
Relay Box: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6272
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6273
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6274
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6275
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6276
Relay Box: Diagrams Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6277
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6278
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6279
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6280
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relays and Modules - Power and
Ground Distribution > Relay Box > Component Information > Diagrams > Junction Block > Page 6281
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Locations
Relay Box: Locations
ABS Fuses
ABS Fuses
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block
Relay Box: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6287
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6288
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6289
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6290
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6291
Relay Box: Diagrams Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6292
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6293
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6294
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6295
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Relay Box > Component Information
> Diagrams > Junction Block > Page 6296
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Interior - Seat Heater Harness Location Revision
Wiring Harness: Technical Service Bulletins Interior - Seat Heater Harness Location Revision
NUMBER: 26-04-99G
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-8105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Starting and Charging > Power and Ground Distribution > Wiring Harness > Component
Information > Technical Service Bulletins > Interior - Seat Heater Harness Location Revision > Page 6301
8N-4
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions
Auxiliary Power Outlet: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6307
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6308
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6309
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6310
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6311
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6312
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6313
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6314
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6315
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6316
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6317
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6318
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6319
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6320
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6321
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6322
Auxiliary Power Outlet: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6323
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6324
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6325
Auxiliary Power Outlet: Electrical Diagrams
Horn/Cigar Lighter/Power Outlet (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Diagram Information and Instructions > Page 6326
Horn/Cigar Lighter/Power Outlet (Part 2 Of 2)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Auxiliary Power Outlet > Component Information > Diagrams
> Page 6327
Auxiliary Power Outlet: Service and Repair
REMOVAL
Outlet Base Removal
1. Look inside and note position of the retaining bosses. 2. Using external snap ring pliers with 90
degree tips. Insert pliers with tips against bosses and squeeze forcing bosses out of base.
Tool For Outlet Removal
3. Pull out the base through mounting ring by gently rocking pliers. A tool can be made to do the
same. 4. Disconnect the base wires. 5. Set base aside. Remove light ring and disconnect wire.
INSTALLATION
1. Position mount ring to the instrument panel and feed the wires through ring. Index the cap and
the mount ring with the index tab at 9 o'clock to the
key in the instrument panel. Install the ring.
2. Connect wires to base. Orient base alignment rib at 11 o'clock to mate the groove in mount ring
at the same location 3. Push base into the bezel till it locks. 4. Install 12 Volt outlet cap and check
operation of outlet or element.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations
Diode: Locations
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6331
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6332
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6333
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Diode > Component Information > Locations > Page 6334
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions
Power Distribution Center: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6339
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6340
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6341
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6342
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6343
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6344
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6345
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6346
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6347
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6348
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6349
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6350
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6351
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6352
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6353
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6354
Power Distribution Center: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6355
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6356
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6357
Power Distribution Center: Connector Views
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6358
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6359
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6360
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6361
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6362
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6363
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6364
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6365
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6366
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6367
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Center <--> [Electrical Accessory Panel] >
Component Information > Diagrams > Diagram Information and Instructions > Page 6368
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center
Fuse: Locations Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6373
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6374
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6375
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6376
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6377
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6378
Fuse: Locations Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6379
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6380
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6381
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse > Component Information > Locations > Power
Distribution Center > Page 6382
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block
Fuse Block: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6387
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6388
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6389
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6390
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6391
Fuse Block: Diagrams Power Distribution Block
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6392
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6393
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6394
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6395
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Fuse Block > Component Information > Diagrams > Junction
Block > Page 6396
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions
Multiple Junction Connector: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6401
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6402
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6403
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6404
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6405
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6406
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6407
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6408
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6409
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6410
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6411
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6412
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6413
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6414
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6415
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6416
Multiple Junction Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6417
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6418
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6419
Multiple Junction Connector: Connector Views
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6420
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6421
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6422
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6423
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6424
Multiple Junction Connector: Electrical Diagrams
Junction Block
Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6425
Junction Block (Part 1 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6426
Junction Block (Part 2 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6427
Junction Block (Part 3 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6428
Junction Block (Part 4 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6429
Junction Block (Part 5 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6430
Junction Block (Part 6 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6431
Junction Block (Part 7 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6432
Junction Block (Part 8 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6433
Junction Block (Part 9 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6434
Junction Block (Part 10 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6435
Junction Block (Part 11 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6436
Junction Block (Part 12 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6437
Junction Block (Part 13 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6438
Junction Block (Part 14 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6439
Junction Block (Part 15 Of 16)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 6440
Junction Block (Part 16 Of 16)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Multiple Junction Connector > Component Information >
Diagrams > Page 6441
Multiple Junction Connector: Service and Repair
Junction Block
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement.
Junction Block
3. Disconnect four, forty-way connectors from Junction Block. 4. Disconnect two wire connectors
from bottom of Body Control Module. 5. Remove bolts holding Junction Block to dash panel
mounting. 6. Remove Junction Block from mounting bracket. 7. Remove screws holding Body
Control Module to Junction Block. 8. Slide Body Control Module downward to disconnect guide
studs on Junction Block from BCM mounting bracket. 9. Separate Junction Block from Body
Control Module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Power Distribution Relay > Component Information >
Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Power Distribution Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Locations
Relay Box: Locations
ABS Fuses
ABS Fuses
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block
Relay Box: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6454
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6455
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6456
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6457
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6458
Relay Box: Diagrams Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6459
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6460
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6461
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6462
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relays and Modules - Power and Ground Distribution >
Relay Box > Component Information > Diagrams > Junction Block > Page 6463
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Locations
Relay Box: Locations
ABS Fuses
ABS Fuses
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block
Relay Box: Diagrams Junction Block
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6469
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6470
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6471
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6472
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6473
Relay Box: Diagrams Power Distribution Center
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6474
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6475
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6476
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6477
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Relay Box > Component Information > Diagrams > Junction
Block > Page 6478
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Interior - Seat Heater Harness Location Revision
Wiring Harness: Technical Service Bulletins Interior - Seat Heater Harness Location Revision
NUMBER: 26-04-99G
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-8105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Power and Ground Distribution > Wiring Harness > Component Information > Technical
Service Bulletins > Interior - Seat Heater Harness Location Revision > Page 6483
8N-4
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using
Alternative Fuels or Electric Engine
Alignment: Specifications Vehicles Using Alternative Fuels or Electric Engine
FRONT:
Individual Camber [1] ...........................................................................................................................
..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed
................................................................................................................................... 0.00° - 0.50°
MAX Individual Caster [2] ....................................................................................................................
............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to
Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ...................................................................................................
........................................................................ +0.05° ± 0.10° Total Toe ............................................
........................................................................................................................................................
+0.10° ± 0.20° Side to Side Toe Differential ........................................................................................
....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle ....................
..............................................................................................................................................................
. 0.00° ± 2.50° Ride Height [7] .............................................................................................................
................................................................... 783.5 mm ± 10.0 mm Ride Height Side to Side
Differential ...........................................................................................................................................
0.0 mm 12.5 mm MAX
REAR:
Individual Camber ................................................................................................................................
...................................................... +0.00° ± 0.25° Individual Toe Right/Left .......................................
...................................................................................................................................... 0.00° ± 0.40°
Total Toe [4, 6] ....................................................................................................................................
......................................................... 0.00° ± 0.40° Thrust Angle [4] ...................................................
........................................................................................................................................ 0.00° ± 0.30°
Ride Height [5, 7] .................................................................................................................................
........................................... 802.5 mm ± 10.0 mm Ride Height Side to Side Differential [5]
...................................................................................................................................... 0.0 mm 12.5
mm MAX
[1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent.
[2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
[3]: Toe-In is positive.
[4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
[5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the
vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the
ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are
not adjustable. If found to be out of specification check for damaged and/or worn out suspension
components and replace as necessary.
[6]: Toe out when backed on alignment rack is toe in when driving.
[7]: Measured at top of fender wheel opening.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using
Alternative Fuels or Electric Engine > Page 6489
Alignment: Specifications With Tire Sizes P205/75/R14 or P215/65/R15
FRONT:
Individual Camber [1] ...........................................................................................................................
..................................................... +0.15° ± 0.40° Camber Side to Side Difference Not to Exceed
................................................................................................................................... 0.00° - 0.50°
MAX Individual Caster [2] ....................................................................................................................
............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to
Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ...................................................................................................
........................................................................ +0.05° ± 0.10° Total Toe ............................................
........................................................................................................................................................
+0.10° ± 0.20° Side to Side Toe Differential ........................................................................................
....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle ....................
..............................................................................................................................................................
. 0.00° ± 2.50° Ride Height [7] .............................................................................................................
................................................................... 747.5 mm ± 10.0 mm Ride Height Side to Side
Differential ...........................................................................................................................................
0.0 mm 12.5 mm MAX
REAR:
Individual Camber ................................................................................................................................
...................................................... +0.00° ± 0.25° Individual Toe Right/Left .......................................
...................................................................................................................................... 0.00° ± 0.40°
Total Toe [4, 6] ....................................................................................................................................
......................................................... 0.00° ± 0.40° Thrust Angle [4] ...................................................
........................................................................................................................................ 0.00° ± 0.30°
Ride Height [5, 7] .................................................................................................................................
........................................... 766.0 mm ± 10.0 mm Ride Height Side to Side Differential [5]
...................................................................................................................................... 0.0 mm 12.5
mm MAX
[1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent.
[2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
[3]: Toe-In is positive.
[4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
[5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the
vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the
ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are
not adjustable. If found to be out of specification check for damaged and/or worn out suspension
components and replace as necessary.
[6]: Toe out when backed on alignment rack is toe in when driving.
[7]: Measured at top of fender wheel opening.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Vehicles Using
Alternative Fuels or Electric Engine > Page 6490
Alignment: Specifications With Tire Sizes P205/75/R15 or P215/65/R16
FRONT:
Individual Camber [1] ...........................................................................................................................
..................................................... +0.05° ± 0.40° Camber Side to Side Difference Not to Exceed
................................................................................................................................... 0.00° - 0.50°
MAX Individual Caster [2] ....................................................................................................................
............................................................... +1.40° ± 1.00° Caster Side to Side Difference Not to
Exceed ..................................................................................................................................... 0.00° 1.00° MAX Individual Toe Right/Left ...................................................................................................
........................................................................ +0.05° ± 0.10° Total Toe ............................................
........................................................................................................................................................
+0.10° ± 0.20° Side to Side Toe Differential ........................................................................................
....................................................................... 0.00° - 0.06° MAX Steering Wheel Angle ....................
..............................................................................................................................................................
. 0.00° ± 2.50° Ride Height [7] .............................................................................................................
................................................................... 753.5 mm ± 10.0 mm Ride Height Side to Side
Differential ...........................................................................................................................................
0.0 mm 12.5 mm MAX
REAR:
Individual Camber ................................................................................................................................
...................................................... +0.00° ± 0.25° Individual Toe Right/Left .......................................
...................................................................................................................................... 0.00° ± 0.40°
Total Toe [4, 6] ....................................................................................................................................
......................................................... 0.00° ± 0.40° Thrust Angle [4] ...................................................
........................................................................................................................................ 0.00° ± 0.30°
Ride Height [5, 7] .................................................................................................................................
........................................... 772.0 mm ± 10.0 mm Ride Height Side to Side Differential [5]
...................................................................................................................................... 0.0 mm 12.5
mm MAX
[1]: Camber is adjustable using the Mopar Camber Adjustment Service Kit, or equivalent.
[2]: Caster is not adjustable. If found to be out of specifications check for proper ride heights and
damaged/worn out suspension components and replace as necessary.
[3]: Toe-In is positive.
[4]: Toe, Camber and thrust angle are not adjustable. If found to be out of specifications check for
proper ride heights and damaged/worn out suspension components and replace as necessary.
[5]: When measuring ride heights: 1) Ensure that the tire pressures are correct. 2) Jounce the
vehicle at the bumper several times and release at the bottom of the stroke. 3) Measure from the
ground to the outboard, lower, center section of the fender wheel well opening. Ride heights are
not adjustable. If found to be out of specification check for damaged and/or worn out suspension
components and replace as necessary.
[6]: Toe out when backed on alignment rack is toe in when driving.
[7]: Measured at top of fender wheel opening.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Specifications > Page 6491
Alignment: Service Precautions
CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle
alignment specifications, by heating and or bending.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Front-End Alignment
Alignment: Description and Operation Front-End Alignment
GENERAL INFORMATION
Wheel alignment is the proper adjustment of all the interrelated suspension angles affecting the
running and steering of the front and rear wheels of the vehicle. The method of checking front and
rear wheel alignment will vary depending on the type of equipment being used. The instructions
furnished by the manufacturer of the equipment should always be followed. With the exception that
the wheel alignment specifications recommended by Chrysler Corporation should always be used.
DESCRIPTION
There are six basic factors which are the foundation to front wheel alignment. These are vehicle
height, caster, camber, toe-in, steering axis inclination and toe-out on turns. Of the six basic factors
only toe-in is normally mechanically adjustable on this vehicle.
Camber Adjustment - is allowed in the event that a vehicle is involved in an accident and after
repairs are made meeting manufacturers tolerance specifications, the camber setting will not meet
manufacturers specifications. If camber adjustment is required, refer to the following Service
Camber Adjustment Procedure for the required steps to be followed.
CAUTION: Do not attempt to modify any suspension or steering components to meet vehicle
alignment specifications, by heating and or bending.
CHECKS AND ADJUSTMENTS
Alignment checks and adjustments should be made in the following sequence: 1. Camber 2. Toe
Camber - is the number of degrees the top of the wheel and tire assembly is tilted inboard or
outboard from a true vertical line. Inboard tilt is negative camber. Outboard tilt is positive camber.
Excessive camber is a tire wear factor: negative camber causes wear on the inside of the tires
tread surface, while positive camber causes wear to the outside of the tires tread surface.
Toe - is measured in degrees or inches and is the distance the front edges of the tires are closer
(or farther apart) than the rear edges.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Front-End Alignment > Page 6494
Alignment: Description and Operation Rear
Alignment adjustment is not required. The rear axle alignment settings are preset at the factory and
therefore no alignment is necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Description and Operation >
Page 6495
Alignment: Testing and Inspection
PRE-WHEEL ALIGNMENT INSPECTION
Before any attempt is made to change or correct the wheel alignment factors. The following part
inspection and the necessary corrections should be made to those parts which influence the
steering of the vehicle. 1. Check and inflate all tires to recommended pressure. All tires should be
the same size and in good condition and have approximately the same
wear. Note the type of tread wear which will aid in diagnosing, refer to Tires.
2. Check front wheel and tire assembly for radial runout. 3. Inspect lower ball joints and all steering
linkage for looseness. 4. Check for broken or sagged front and rear springs. 5. Check vehicle ride
height to verify it is within specifications. 6. Alignment MUST only be checked after the vehicle has
the following areas inspected and or adjusted. Recommended tire pressures, full tank
of fuel, no passenger or luggage compartment load and is on a level floor or a properly calibrated
alignment rack.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking
Caster and Camber
Alignment: Service and Repair Checking Caster and Camber
NOTE: All alignment specifications are to be checked and adjusted with the vehicle at its correct
ride height.
GENERAL INFORMATION
Front suspension Caster and Camber settings on this vehicle are determined at the time the
vehicle is designed. This is done by determining the precise mounting location of the vehicle's
suspension components throughout the design and assembly processes of the vehicle. This is
called a Net Build vehicle and results in no normal requirement to adjustment the Caster and
Camber after a vehicle is built or when servicing the suspension components. Thus Caster and
Camber are not normally considered an adjustable specification when performing an alignment on
this vehicle. Though Caster and Camber are not adjustable they should be checked during the
alignment procedure to ensure they meet the manufacturers specifications.
PROCEDURE
If front camber does not meet the vehicle alignment specifications, it can be adjusted using a
Mopar (R) Service Kit, or equivalent developed to allow for camber adjustment. If a vehicle's front
camber does not meet required specifications, the vehicles suspension components should be
inspected for any signs of damage or bending and the vehicle ride height should be checked to
verify it is within required specification. This inspection must be done before using the Mopar (R)
Service Kit for setting camber to the vehicle specification.
CAUTION: Do not attempt to adjust the vehicles Caster or Camber by heating bending or by
performing any other modification to the vehicle's front suspension components.
1. Correctly position the vehicle on the alignment rack. Then install all required alignment
equipment on the vehicle, per the alignment equipment
manufacturers specifications.
NOTE: Prior to reading each alignment specification, front and rear of vehicle should be jounced an
equal number of times. Induce jounce (rear first then front) by grasping center of bumper and
jouncing each end of vehicle an equal number of times. Bumper should always be released when
vehicle is at the bottom of the jounce cycle.
2. Correctly jounce vehicle and then read the vehicle's current front and rear alignment settings.
Compare the vehicle's current alignment settings
to the vehicle specifications for camber, caster and Toe-in. If front and rear camber readings are within required specifications proceed to Setting Front Toe for
the Toe-in adjustment procedure if required. See: Front Alignment
- If Camber readings are not within specifications refer to Setting Camber Adjustment and Cam Bolt
Installation. See: Setting Camber Adjustment and Cam Bolt Installation
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking
Caster and Camber > Page 6498
Alignment: Service and Repair Front Alignment
1. Prepare vehicle as described in the Pre-Alignment Vehicle Inspection procedure. 2. Center
steering wheel and lock in place using a steering wheel clamp.
CAUTION: Do not twist front inner tie rod to steering gear rubber boots during front wheel Toe
adjustment.
3. Loosen front inner to outer tie rod end jam nuts. Grasp inner tie rods at serrations and rotate
inner tie rods of steering gear to set front Toe to the
preferred Toe specification.
4. Tighten tie rod jam nuts to 75 Nm (55 ft. lbs.) torque. 5. Adjust steering gear to tie rod boots at tie
rod. 6. Remove steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking
Caster and Camber > Page 6499
Alignment: Service and Repair Setting Camber Adjustment and Cam Bolt Installation
1. If the front camber readings obtained are not within the vehicle's specifications, use the following
procedure and the Mopar (R) Clevis Bolt
Service Kit, or equivalent to provide camber adjustment. The kit contains 2 flange bolts, 2 cam
bolts, and 2 dog bone washers. These components of the service kit are necessary to assemble
the strut to the steering knuckle, after modification of the strut clevis bracket.
2. Verify that the strut and steering knuckle are not bent or otherwise damaged. If either component
is bent or show other signs of damage, replace
required components and check the camber setting again.
3. If no component is bent or damaged, use the following procedure for modifying the strut clevis
bracket and adjusting the camber setting. 4. Raise front of vehicle until tires are not supporting the
weight of the vehicle. Then remove wheel and tire assembly from the location on the
vehicle requiring the strut to be modified.
CAUTIONS: When removing the steering knuckle from the strut clevis bracket, do not put a strain on the brake
flex hose. Also, do not let the weight of the steering knuckle assembly be supported by the brake
flex hose when removed from the strut assembly. If necessary use a wire hanger to support the
steering knuckle assembly or if required remove the brake flex hose from the caliper assembly.
- The steering knuckle strut assembly attaching bolts are serrated and must not be turned during
removal. Remove nuts while holding bolts stationary in the steering knuckles.
5. Remove the top and bottom, strut clevis bracket to steering knuckle attaching bolts and discard.
Separate the steering knuckle from the Strut clevis
bracket and position steering knuckle so it is out of the way of the strut.
CAUTION: When slotting the bottom mounting hole on the strut clevis bracket, do not enlarge the
hole beyond the indentations on the sides of the strut clevis bracket.
6. Using an appropriate grinder and grinding wheel slot the bottom hole in both sides of the strut
clevis bracket. When grinding slot do not go beyond
the indentation area on the sides of the clevis bracket.
CAUTION: After slotting the strut clevis bracket hole, do not install the original attaching bolts when
assembling the steering knuckle to the strut assembly. Only the flange bolts, cam bolts, and dog
bone washers from the Mopar (R) Clevis Bolt Service Kit, or equivalent can be used to attach the
steering knuckle to the strut after the mounting hole is slotted.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Alignment > System Information > Service and Repair > Checking
Caster and Camber > Page 6500
7. Install the flanged bolt from the Mopar (R) Clevis Bolt Service Kit, or equivalent into the top clevis
bracket to steering knuckle mounting hole.
Install the cam bolt into the bottom clevis bracket to steering knuckle mounting hole.
8. Install the dog bone washer on the steering knuckle to strut clevis bracket attaching bolts. Then
install the nuts from the original attaching bolts
onto the replacement bolts from the service kit. Tighten the bolts just enough to hold the steering
knuckle in position when adjusting camber, while still allowing the steering knuckle to move in
clevis bracket.
9. Lower vehicle until the full weight of the vehicle is supported by the vehicles' suspension. Then
correctly jounce the front and rear of vehicle an
equal amount of times.
10. Adjust the front camber to the preferred setting by rotating the lower eccentric cam bolt against
the cam stop areas on the strut clevis bracket.
When camber is correctly set, tighten the upper strut clevis bracket bolt and lower cam bolt. Again
jounce front and rear of vehicle an equal amount of times and verify front camber setting.
11. When vehicle is at correct camber setting torque both front strut to steering knuckle attaching
bolts to 90 Nm (65 ft. lbs.) plus an additional 1/4
turn after required torque is met.
12. If Toe readings obtained are not within the required specification range, adjust Toe to meet the
preferred specification setting.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications
Front Steering Knuckle: Specifications
Ball Joint Stud To Steering Knuckle Nut/Bolt
..................................................................................................................................... 136 Nm (100
ft. lbs.) Wheel Stop ..............................................................................................................................
................................................................. 95 Nm (70 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 6505
Front Steering Knuckle: Service Precautions
CAUTION: The front suspension knuckle is not a repairable component of the vehicles front
suspension IT MUST BE REPLACED. If bent, broken or damaged in any way, do not attempt to
straighten or repair the steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Specifications > Page 6506
Front Steering Knuckle: Description and Operation
The steering knuckle is a single casting with legs machined for attachment of the strut damper,
steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has
the front hub/bearing assembly mounted to it. The hub is positioned through the bearing and
knuckle, with the constant velocity stub shaft splined through the hub.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal
Front Steering Knuckle: Service and Repair Removal
1. Raise vehicle on jack stands or centered on a frame contact type hoist.
2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire
assembly from the vehicle.
4. Remove the wave washer from the end of the stub axle.
CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be supported by the tires.
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to
hub nut.
6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6509
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined abutment on steering knuckle.
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut
assembly. Do not allow the brake caliper assembly to
hang by the brake flex hose.
9. Remove the brake rotor from the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6510
10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with a wrench.
Tie Rod End Removal From Steering Knuckle Arm
11. Remove the tie rod end from steering knuckle using Remover, Special Tool MB-991113, or
equivalent.
12. Remove the front wheel speed sensor from the steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6511
13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt
when assembling the steering knuckle to the ball joint
, the pinch bolt must be installed from the rear facing the front on the vehicle.
14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle.
15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when
separating ball joint stud from steering knuckle, so ball
joint seal does not get cut.
NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly
in steering knuckle, end of driveshaft must be supported.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6512
16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft
assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during removal. Remove nuts while holding bolts stationary in the steering knuckles.
17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the
steering knuckle from the strut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6513
Front Steering Knuckle: Service and Repair Installation
1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to
Transmission and Drivetrain.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
NOTE: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.
2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper
to steering knuckle attaching bolts. Tighten both
attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn.
3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the
stud of the ball joint assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6514
4. Install a NEW steering knuckle to ball joint stud, clamping bolt and nut. Tighten the clamping bolt
and nut to a torque of 145 Nm (105 ft. lbs.).
5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32
socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32
socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6515
6. Install braking disc on hub and bearing assembly.
7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom
of caliper under abutment on steering knuckle,
and then rotating top of caliper against top abutment.
8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake
caliper assembly attaching bolts to a torque of 35 Nm
(30 ft. lbs.).
9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6516
10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor
attaching bolt to a torque of 7 Nm (60 inch lbs.). 11. Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the
required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
12. Lower vehicle.
13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of
203 Nm (150 ft. lbs.). 14. Install the spring wave washer on the end of the stub axle.
15. Install the hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut
lock as shown. 16. Set front Toe on vehicle to required specification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage
Power Steering Fluid: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Voyager/Caravan
2002 (PG) Chrysler PT Cruiser (International Markets)
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler
2002 - 2004 (PT) Chrysler PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/Caravan/Voyager
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe
1997 - 2004 (TJ) Wrangler
2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6522
1999-2004 (WJ) Grand Cherokee
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH
vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved
service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and
MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is
no longer an indication of fluid condition.
The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number
for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA.
MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On
some past models, MS9602 should be used as the replacement fluid. On these models, if a power
steering system is being serviced that results in a large fluid loss, such as a pump, hose or
gear/rack replacement, the complete system should be drained and filled with MS9602.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6523
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6524
NOTE:
This bulletin supersedes owner's and service manuals for the vehicles listed above that may state
to use MS9933 in the power steering system, and that may state not to use automatic transmission
fluid in the power steering system.
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications
Power Steering Fluid: Capacity Specifications
Capacity ...............................................................................................................................................
....................................................... 0.81 L (1.7 pints)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Capacity Specifications > Page 6527
Power Steering Fluid: Fluid Type Specifications
The recommended lubricant is Mopar Power Steering Fluid.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid > Component
Information > Specifications > Page 6528
Power Steering Fluid: Service and Repair
WARNING: Fluid level should be checked with engine off to prevent injury from moving parts.
CAUTION: Do not use automatic transmission fluid in the power steering system. Do not overfill the
power steering system.
Wipe reservoir filler cap free of dirt. Then check fluid level. The dipstick should indicate COLD
when fluid is at normal ambient temperature, approximately 21°C to 27°C (70°F to 80°F). In all
pumps add fluid as necessary, use only Mopar Power Steering Fluid, or equivalent. DO NOT USE
ANY TYPE OF AUTOMATIC TRANSMISSION FLUID.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair
Power Steering Fluid Reservoir: Service and Repair
REMOVE
1. Remove the filler cap prom remote power steering fluid reservoir. 2. Raise vehicle on jack stands
or centered on a frame contact type hoist. 3. Remove at power steering pump, the power steering
fluid hose coming from the power steering fluid reservoir. Let the power steering fluid drain
out of the reservoir and hose.
4. Lower vehicle. 5. Remove the fluid supply hose from the remote power steering fluid reservoir. 6.
Remove the 2 mounting screws attaching the remote fluid reservoir to the inner fender. 7. Remove
remote reservoir from inner fender.
INSTALL
1. Install remote power steering fluid reservoir on inner fender, by first inserting tab on reservoir into
hole in inner fender. Then rotate reservoir so
mounting tabs are against inner fender.
2. Install and securely tighten the 2 reservoir mounting screws.
Power Steering Fluid Hose Routing Clip
CAUTION: The reservoir to power steering hose must be routed tightly against the strut tower and
parallel to the dash panel. It must also be routed under the wiring harness and below the drip tube.
This will prevent the hose from coming in contact with the accessory drive belt.
3. Install the fluid supply hose onto the power steering fluid reservoir fitting. Install the hose clamp
on the fluid supply hose at the fluid reservoir. Be
sure hose clamp is installed past bead on fluid reservoir fitting.
4. Raise vehicle on jack stands or centered on a frame contact type hoist. 5. Install power steering
fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose at the
power steering pump. Be
sure hose clamp is installed past bead on pump flitting.
6. Lower vehicle. 7. Install routing clip for power steering fluid supply hose on stud in strut tower. 8.
Fill the remote fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
9. Start the engine and let run for a few seconds. Then turn the engine off.
10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after
running the engine. 11. Raise the front wheels off the ground.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Fluid Reservoir >
Component Information > Service and Repair > Page 6532
12. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the wheel stops.
13. Add power steering fluid if necessary. 14. Lower the vehicle and turn the steering wheel slowly
from lock to lock. 15. Stop the engine. Check the fluid level and refill as required. 16. If the fluid is
extremely foamy, allow the vehicle to stand a few minutes and repeat the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6541
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6542
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6543
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6544
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6545
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-05-98 > Aug
> 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6546
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec
> 97 > Power Steering Line - Honk Noise At Low Speed
Technical Service Bulletin # 19-11-97 Date: 971205
Power Steering Line - Honk Noise At Low Speed
NO: 19-11-97
GROUP: Steering
EFFECTIVE DATE: Dec. 5, 1997
SUBJECT: "Honk" Noise During Parking Lot Maneuvers
FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN
SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR
VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE
BULLETIN 19-07-97.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR
3.8L ENGINE.
SYMPTOM/CONDITION:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
DIAGNOSIS:
The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it
may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise
can be reproduced during the diagnostic procedure. The noise may decrease in severity or
disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings,
replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic
procedure is performed, will temporarily eliminate the noise for approximately 200 miles.
Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly
move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform
the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering
wheel back toward the right, repeat several times. If the noise is heard, perform the Repair
Procedure.
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011 873AA Line, Power Steering Return
AR 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 19-50-17-90 0.4 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing revised power steering pressure and return lines.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec
> 97 > Power Steering Line - Honk Noise At Low Speed > Page 6551
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1.
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear, Figure 2.
Discard the line and screw clamp.
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting,
Figure 3.
9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2.
Remove and discard the power steering pressure line.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec
> 97 > Power Steering Line - Honk Noise At Low Speed > Page 6552
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line, Figure 4.
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line on to the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in.
lbs.) Figure 2.
18. POWER STEERING FLUID LEVEL ADJUSTMENT
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Customer Interest for Power Steering Line/Hose: > 19-11-97 > Dec
> 97 > Power Steering Line - Honk Noise At Low Speed > Page 6553
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
19. Verify correct steering operation and no fluid leaks.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6559
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6560
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6561
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6562
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6563
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed > Page 6564
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed
Technical Service Bulletin # 19-11-97 Date: 971205
Power Steering Line - Honk Noise At Low Speed
NO: 19-11-97
GROUP: Steering
EFFECTIVE DATE: Dec. 5, 1997
SUBJECT: "Honk" Noise During Parking Lot Maneuvers
FOR VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR 3.8L ENGINE THIS BULLETIN
SUPERSEDES TECHNICAL SERVICE BULLETIN 19-07-97, DATED MAY 9, 1997. FOR
VEHICLES EQUIPPED WITH A 2.4L ENGINE CONTINUE TO USE TECHNICAL SERVICE
BULLETIN 19-07-97.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES EQUIPPED WITH A 3.0L, 3.3L OR
3.8L ENGINE.
SYMPTOM/CONDITION:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
DIAGNOSIS:
The noise may or may not go away after the vehicle has been operated for 10-15 minutes, so it
may be necessary to not operate the vehicle for approximately 60 minutes or more before the noise
can be reproduced during the diagnostic procedure. The noise may decrease in severity or
disappear when the ambient temperature is below 7°C (45°F). Any break, (loosening fittings,
replacing pump or lines) made in the Power Steering (P/S) fluid system before the diagnostic
procedure is performed, will temporarily eliminate the noise for approximately 200 miles.
Start the engine and turn the steering wheel to the right until it reaches the stop. Jerk (quickly
move) the steering wheel back toward the left, repeat several times or if the noise is heard, perform
the Repair Procedure. Turn the steering wheel to the left until it reaches the stop. Jerk the steering
wheel back toward the right, repeat several times. If the noise is heard, perform the Repair
Procedure.
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011 873AA Line, Power Steering Return
AR 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 19-50-17-90 0.4 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves installing revised power steering pressure and return lines.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6569
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line, Figure 1.
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear, Figure 2.
Discard the line and screw clamp.
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting,
Figure 3.
9. Disconnect the power steering pressure line from the power steering gear assembly, Figure 2.
Remove and discard the power steering pressure line.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6570
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINES, FIGURE 4. DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle, Figure 4. Torque the bolt to 16 Nm (150 in. lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line, Figure 4.
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line on to the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear to 27-35 Nm (240- 310 in.
lbs.) Figure 2.
18. POWER STEERING FLUID LEVEL ADJUSTMENT
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Power Steering Line/Hose: >
19-11-97 > Dec > 97 > Power Steering Line - Honk Noise At Low Speed > Page 6571
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
19. Verify correct steering operation and no fluid leaks.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Technical Service Bulletins > Page 6572
Power Steering Line/Hose: Specifications
Hose Tube Nuts ...................................................................................................................................
..................................................... 34 Nm (25 ft. lbs.) Routing Bracket To Suspension Cradle
.................................................................................................................................................... 28
Nm (21 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump
Power Steering Line/Hose: Service and Repair Supply Hose From Reservoir to Pump
REMOVE
1. Remove the filler cap from remote power steering fluid reservoir. 2. Using a siphon pump,
remove as much power steering fluid as possible from the power steering fluid reservoir.
Power Steering Fluid Hose Routing Clip
3. Remove power steering fluid supply hose routing clip from stud in strut tower. 4. Raise vehicle
on jack stands or centered on a frame contact type hoist. 5. Remove at power steering pump, the
power steering fluid hose coming from the power steering fluid reservoir. Let the power steering
fluid drain
out of the reservoir and hose.
6. Lower vehicle. 7. Remove hose clamp attaching the power steering fluid supply hose to the
power steering fluid reservoir. 8. Remove the power steering fluid supply hose from the vehicle.
Hose is removed from the top of the engine compartment.
INSTALL
CAUTION: On V-6 engine applications, the power steering fluid reservoir to power steering hose
must be routed tightly against the strut tower and parallel to the dash panel. It must also be routed
under the wiring harness and below the drip tube. This routing will prevent the power steering fluid
supply hose from coming in contact with the accessory drive belt.
1. Install and correctly route the power steering fluid supply hose from remote fluid reservoir down
to power steering pump. 2. Install the fluid supply hose onto the power steering fluid reservoir.
Install the hose clamp on the fluid supply hose. Be sure hose clamp is installed
past bead on fluid reservoir fitting.
3. Raise vehicle on jack stands or centered on a frame contact type hoist. 4. Install power steering
fluid supply hose on power steering pump. Install the hose clamp on the fluid supply hose. Be sure
hose clamp is installed
past bead on pump fitting.
5. Lower vehicle. 6. Install routing clip on power steering fluid supply hose. Be sure routing clip is
installed in a position to correctly align with stud in strut tower. 7. Install routing clip for power
steering fluid supply hose on stud in strut tower. 8. Fill the remote fluid reservoir to the proper let
and let the fluid settle for at least two (2) minutes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6575
9. Start the engine and let run for a few seconds. Then turn the engine off.
10. Add fluid if necessary. Repeat the above procedure until the fluid level remains constant after
running the engine. 11. Raise the front wheels off the ground. 12. Start the engine. Slowly turn the
steering wheel right and left, lightly contacting the wheel stops. 13. Add power steering fluid if
necessary. 14. Lower the vehicle and turn the steering wheel slowly from lock to lock. 15. Stop the
engine. Check the fluid level and refill as required. 16. If the fluid is extremely foamy, allow the
vehicle to stand a few minutes and repeat the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6576
Power Steering Line/Hose: Service and Repair Power Steering Fluid Pressure Hose
WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if
engine has been running.
CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch
hot exhaust manifold or catalyst.
NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses,
power steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the heat sleeve on the power steering fluid return hose to expose the return hose to steel
tube connection. Remove the hose clamp from the
power steering fluid return hose. Remove power steering fluid return hose from steel tube and
allow power steering fluid to drain from pump.
5. Remove the power steering fluid pressure line from the power steering pump pressure fitting.
Drain excess power steering fluid from hose.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6577
6. Remove bolt, attaching power steering hose routing bracket to front suspension cradle.
7. Disconnect power steering hose at power steering gear assembly. Drain the power steering fluid
from power steering pump and hose. 8. Discard the O-rings on the ends of power steering fluid
pressure hose.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends, power steering pump
pressure fitting and steering gear ports. 2. Install new O-rings on the ends of the power steering
fluid pressure hose. Lubricate O-rings using clean power steering fluid. 3. Attach the power
steering pressure hose to the fittings on the power steering pump and steering gear. Route hose
avoiding tight bends or kinking.
Do not bend tube ends of the power steering hoses when installing.
4. Install the power steering fluid hoses to suspension cradle routing bracket. Power steering fluid
hoses must remain away from the exhaust system
and must not come in contact with any unfriendly surfaces of the vehicle.
CAUTION: When tightening and torquing the pressure hose at the power steering pump, the
pressure hose is to be rotated against the fluid return hose fitting on the pump.
5. Tighten all fasteners shown for specific applications to their correct torques listed below:
- Pump End Tube Nut: 34 Nm (25 ft. lbs.)
- Gear End Tube Nut: 34 Nm (25 ft. lbs.)
- Pump Bracket Nut: 40 Nm (30 ft. lbs.)
6. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 7.
Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6578
CAUTION: The protective heat sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses.
8. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
9. After hoses are installed and power steering system is filled with fluid and cap is installed on
reservoir. Start the engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Line/Hose >
Component Information > Service and Repair > Supply Hose From Reservoir to Pump > Page 6579
Power Steering Line/Hose: Service and Repair Power Steering Fluid Return Hose
WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if
engine has been running.
CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch
hot exhaust manifold or catalyst.
NOTE: Service all power steering hoses with vehicle raised on hoist. Cap all open ends of hoses,
power steering pump fittings and steering gear ports to prevent entry of foreign material into the
components.
REMOVE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. Raise vehicle. Put oil
drain pan under vehicle to catch power steering fluid.
4. Raise the insulating heat sleeve on the power steering hoses to expose the hose to steel tube
connection. Remove hose clamp where rubber portion
of power steering fluid return hose attaches to steel tube on suspension cradle. Remove rubber
hose from steel tube and allow power steering fluid to drain from pump.
5. Remove the power steering fluid return hose from the power steering pump return hose fitting.
INSTALL
1. Using a lint free towel, wipe clean the open power steering hose ends and power steering pump
fitting. 2. Attach the power steering return hose to the fitting on the power steering pump. Route
hose smoothly avoiding tight bends or kinking. Hose must
remain away from the exhaust system and not come in contact with any unfriendly surfaces of the
vehicle.
3. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 4.
Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is to prevent
overheating of the power steering fluid hoses.
5. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
6. After hoses are installed and power steering system is filled with fluid and caps installed on
reservoir. Start the engine and check for leaks.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage
Power Steering Pump: Technical Service Bulletins Steering - Power Steering Fluid Usage
NUMBER: 19-005-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-007-01, DATED AUG. 2, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. THIS IS A COMPLETE REVISION AND NO
ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
SUBJECT: Power Steering Fluid Usage
MODELS:
1993 - 2003 (AB) Ram Van
1994 - 2004 (AN) Dakota
1994 - 2002 (BR/BE) Ram Pickup
2004 (CS) Pacifica
1998-2004 (DN) Durango
2002 - 2004 (DR) Ram Pickup
1996 - 2000 (GS) Chrysler Voyager (International Markets)
1995 - 2000 (JA) Cirrus/Stratus/Breeze
2001 - 2004 (JR) Sebring Sedan, Stratus Sedan1 Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 - 2004 (KJ) Liberty
2002 - 2004 (KJ) Cherokee (International Markets)
1993 - 2004 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Voyager/Caravan
2002 (PG) Chrysler PT Cruiser (International Markets)
1995-2004 (PL) Neon
1997 - 2003 (PR) Prowler
2002 - 2004 (PT) Chrysler PT Cruiser
2001 - 2004 (RG) Chrysler Voyager (International Markets)
2001 - 2004 (RS) Town & Country/Caravan/Voyager
1993 - 2002 (SR) Viper/Viper Coupe
2001 - 2004 (ST) Sebring Coupe/Stratus Coupe
1997 - 2004 (TJ) Wrangler
2003 - 2004 (VA) Sprinter
1999 - 2004 (WG) Grand Cherokee (International Markets)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6584
1999-2004 (WJ) Grand Cherokee
2003 - 2004 (ZB) Viper
2004 (ZH) Crossfire
DISCUSSION:
The factory fill power steering fluid for most 2004 model year Chrysler Group vehicles is ATF+4
(MS9602) and it provides superior performance at both low and high temperatures. WJ/WG and ZH
vehicles use unique power steering fluids. Refer to the table to identify factory fill and the approved
service power steering fluid by year and model. Note that MS9602 is Red in color and MS5931 and
MS9933 are Amber/Yellow in color. All three fluids will darken in color with usage and fluid color is
no longer an indication of fluid condition.
The part numbers for MS9602 are 05013457AA (quart) and 05013458AA (gallon). The part number
for MS5931 is 04883077 (quart). The part number for MB345 is 05127381AA.
MS9602 should not be mixed or used as a "topping off" fluid on systems requiring MS5931. On
some past models, MS9602 should be used as the replacement fluid. On these models, if a power
steering system is being serviced that results in a large fluid loss, such as a pump, hose or
gear/rack replacement, the complete system should be drained and filled with MS9602.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6585
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Technical Service Bulletins > Steering - Power Steering Fluid Usage > Page 6586
NOTE:
This bulletin supersedes owner's and service manuals for the vehicles listed above that may state
to use MS9933 in the power steering system, and that may state not to use automatic transmission
fluid in the power steering system.
POLICY: Information Only.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications
Power Steering Pump: Mechanical Specifications
Flow Control Valve Fitting ....................................................................................................................
................................................... 75 Nm (55 ft. lbs.) Mounting Bolts ...................................................
...................................................................................................................................... 54 Nm (40 ft.
lbs.) Rear Bracket To Engine Mounting Bolts
.................................................................................................................................................. 54 Nm
(40 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Mechanical Specifications > Page 6589
Power Steering Pump: Pressure, Vacuum and Temperature Specifications
Flow at 1500 RPM & Min. Pressure
............................................................................................................................ 5.0 - 7.0 Liters/Min
(1.3 - 1.9 GPM) Control Valve Pressure Relief
....................................................................................................................................... 9653 - 10342
kPa (1400 - 1500 psi)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Specifications > Page 6590
Power Steering Pump: Description and Operation
Hydraulic pressure for the operation of the power steering gear is provided by a belt driven power
steering pump. The power steering pump is a constant flow rate and displacement vane type
pump. The power steering pump used on all applications is the Vane-Submerged remote reservoir
style power steering pump.
The remote reservoir type pump has the pump housing and internal components combined with the
fluid housing. But it has a remote reservoir for the power steering fluid supply.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement
Power Steering Pump: Service and Repair Power Steering Pump Flow Control Valve Seal
Replacement
WARNING: Power steering oil, engine parts and the exhaust system may be extremely hot if
engine has been running. Do not start engine with any loose or disconnected hoses. Do not allow
hoses to touch hot exhaust manifold or catalyst.
DISASSEMBLE
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir.
3. Raise vehicle. Put oil drain pan under vehicle to catch power steering fluid. 4. Raise the heat
sleeve on the power steering return hose to expose the return hose to steel tube connection.
Remove hose clamp from power steering
fluid return hose. Remove power steering return hose from steel tube and allow remaining power
steering fluid to drain from power steering pump and reservoir.
5. Remove the power steering fluid pressure line from the power steering pump pressure fitting.
Drain excess power steering fluid from hose. 6. Remove the pressure fitting/flow control valve from
the power steering pump and remove and discard the O-Ring seal.
ASSEMBLE
1. Install a new O-Ring seal on the pressure fitting/flow control valve, and wet the O-Ring with
clean fresh power steering fluid. 2. Install the pressure fitting/flow control valve in the power
steering pump. Tighten the pressure fitting/flow control valve to a torque of 75 Nm (55
ft. lbs.).
CAUTION: When tightening and torquing the pressure hose at the power steering pump, the hose
should be rotated against the fluid return hose fitting on the pump.
3. Install the power steering fluid pressure hose in the pressure fitting/flow control valve. Tighten
the tube nut to a torque of 34 Nm (25 ft. lbs.). 4. Install the power steering fluid return hose on the
steel tube at the front suspension cradle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6593
5. Install a screw type hose clamp on the power steering hose to steel tube connection. Tighten the
screw clamp to a torque of 2 Nm (18 inch lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is required to
keep the power steering hoses from becoming overheated.
6. When used, properly position the protective heat sleeves on the power steering hoses. Then, tie
strap the heat sleeves to the power steering hoses
to keep them in their proper position.
7. Fill the power steering system with fluid, bleed air from system and check that power steering
fluid is at correct level.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6594
Power Steering Pump: Service and Repair Power Steering Pump Initial Operation
WARNING: The fluid level should be checked with engine off to prevent injury from moving
components.
CAUTION: Use only Mopar Power Steering Fluid. Do not use automatic transmission fluid. Do not
overfill.
Wipe filler cap clean, then check the fluid level. The dipstick should indicate FULL COLD when the
fluid is at normal temperature of approximately 21° C to 27°C (70°F to 80°F).
1. Fill the pump fluid reservoir to the proper level and let the fluid settle for at least two (2) minutes.
2. Start the engine and let run for a few seconds. Then turn the engine off. 3. Add fluid if necessary.
Repeat the above procedure until the fluid level remains constant after running the engine. 4. Raise
the front wheels off the ground. 5. Start the engine. Slowly turn the steering wheel right and left,
lightly contacting the wheel stops. 6. Add power steering fluid if necessary. 7. Lower the vehicle
and turn the steering wheel slowly from lock to lock. 8. Stop the engine. Check the fluid level and
refill as required. 9. If the fluid is extremely foamy, allow the vehicle to stand a few minutes and
repeat the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6595
Power Steering Pump: Service and Repair Power Steering Pump Pulley Replacement
REMOVE
1. Remove the pulley from the shaft of the power steering pump using Puller C-4333 or C-4068, or
equivalent.
CAUTION: Do not hammer on power steering pump pulley. This will damage the pulley and the
power steering pump.
2. Replace pulley if it is found to be bent, cracked, or loose.
INSTALL
1. Install the pulley with Installer C-4063, or equivalent. Do not use the tool adapters. 2. Ensure that
the tool and the pulley remain aligned with the pump shaft. Prevent the pulley from being cocked
on the shaft.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6596
3. Force pulley flush with the end of the power steering rums shaft. 4. With serpentine belts, run
engine until warm (5 min.) and note any belt chirp. If chirp exists, move pulley outward
approximately 0.5 mm (0.020
inch). If noise increases, press on 1.0 mm (0.040 inch). Be careful that pulley does not contact
mounting bolts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6597
Power Steering Pump: Service and Repair Power Steering Pump Removal and Installation
Installation
1. Install power steering pump back in vehicle using the reverse order of its removal through the
exhaust tunnel of the vehicle.
2. Install the power steering pump on its mounting bracket. Install the 3 power steering pump
mounting bolts. Tighten the power steering pump
mounting bolts to a torque of 54 Nm (40 ft. lbs.).
3. Install the support bracket attaching rear of power steering pump to engine. Tighten the nut and
bolt holding the strut assembly to bracket and the
intake manifold stud to a torque of 54 Nm (40 ft. lbs.).
NOTE: Before installing power steering pressure hose on power steering pump, inspect the O-ring
on the power steering pressure hose for damage and replace if required.
4. Install the power steering fluid pressure line onto the output fitting of the power steering pump.
Tighten the pressure line to pump fitting tube nut
to a torque of 31 Nm (275 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6598
5. Install the power steering fluid, low pressure return hose on the power steering pump low
pressure fitting. Be sure hose clamps are properly
reinstalled.
6. Install the power steering fluid supply hose from the power steering fluid reservoir, on the power
steering pump fluid fitting. Be sure hose is clear
of accessory drive belts and all hose clamps are properly reinstalled.
7. Install the serpentine drive belt. Refer to Engine.
8. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 9.
Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose
clamps are properly reinstalled. Tighten the
screw clamp to a torque of 2 Nm (18 inch lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering fluid pressure and return hoses. This is required to
keep the power steering hoses from becoming overheated.
10. When used, properly position the protective heat sleeves on the power steering hoses. Then,
tie strap the heat sleeves to the power steering hoses
to keep them in their proper position.
11. Install the exhaust pipe on the exhaust manifold. Install all exhaust system hangers/isolators on
the exhaust system brackets. 12. Connect the oxygen sensor wiring harness to the vehicle wiring
harness. Install wiring harness grommet in the floor pan of the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6599
13. Install the accessory drive splash shield. 14. Lower vehicle.
CAUTION: Do not use automatic transmission fluid in power steering system. Only use Mopar,
Power Steering Fluid, or equivalent.
15. Fill the remote power steering pump fluid reservoir to correct fluid level. 16. Install cap on power
steering fluid reservoir. 17. Connect the negative battery cable on the negative battery post. 18.
Start engine and turn steering wheel several times from stop to stop to bleed air from fluid in
system. Stop engine, check fluid level, and inspect
system for leaks.
Removal
WARNING: Power steering oil, engine components and the exhaust system may be extremely hot
if engine has been running.
CAUTION: Do not start engine with any loose or disconnected hoses. Do not allow hoses to touch
hot exhaust manifold or catalyst.
1. Remove the (-) negative battery cable from the battery and isolate cable. 2. Remove cap from
power steering fluid reservoir. 3. Using a siphon pump, remove as much power steering fluid as
possible from the power steering fluid reservoir. 4. Raise vehicle on jack stands or centered on a
frame contact type hoist. 5. Disconnect the oxygen sensor wiring harness from the vehicle wiring
harness. Access to connection at vehicle wiring harness is through the
oxygen sensor wiring harness grommet in the floor pan of the vehicle.
NOTE: The exhaust system needs to be removed from the engine to allow for an area to remove
the power steering pump from the vehicle.
6. Remove the catalytic converter from the exhaust manifold. Then remove all the exhaust system
hangers/isolators from the brackets on the exhaust
system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6600
7. Move the exhaust system as far rearward and to the left side of the vehicle as possible.
8. Raise the heat sleeve on the power steering hoses to expose the hose to steel tube connection.
Remove the hose from the power steering fluid
return line on the front suspension cradle. Allow the remaining power steering fluid to drain from the
pump and fluid reservoir through the removed return hose.
9. Remove the accessory drive splash shield.
10. Remove the serpentine accessory drive belt from the engine. Refer to Engine.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Service and Repair > Power Steering Pump Flow Control Valve Seal Replacement > Page 6601
11. Remove the power steering fluid supply hose coming from the remote fluid reservoir, from the
fitting on the power steering pump. Drain off
excess power steering fluid from hose.
12. Remove the power steering fluid pressure line from the power steering pump. Drain excess
power steering fluid from tube. 13. Remove the power steering fluid return hose from the power
steering pump. Drain excess power steering fluid from tube.
14. Remove the support bracket at the rear of the power steering pump attaching the pump to the
rear of the engine.
15. Remove the 3 bolts mounting the power steering pump to the alternator/power steering pump
and belt tensioner mounting bracket. 16. Remove the power steering pump from its mounting
bracket. 17. The power steering pump is removed from the vehicle by pulling it out through the
exhaust tunnel area in the floor pan of the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Tools and Equipment > Power Steering System Analyzer 6815
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 6604
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Power Steering > Power Steering Pump > Component
Information > Tools and Equipment > Power Steering System Analyzer 6815 > Page 6605
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Air Bag(s) Arming and Disarming >
System Information > Service and Repair > Air Bag Disarming > Page 6612
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover >
Component Information > Service and Repair
Steering Column Cover: Service and Repair
REMOVAL
Park Brake Release Handle
1. Remove screws holding parking brake release handle to instrument panel.
Lower Steering Column Cover
2. Remove screws holding bottom of lower steering column cover to instrument panel. 3. Remove
screw holding right side of lower steering column cover to instrument panel.
Park Brake Release Handle
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Steering Column Cover >
Component Information > Service and Repair > Page 6616
4. Disengage park brake release cable case from groove on end of release handle. 5. Disengage
cable end pivot from slot on release handle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area
Technical Service Bulletin # 19-003-03 Date: 030829
Steering Column - Pop/Tick From Steering Wheel Area
NUMBER: 19-003-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE
CORRECTING VEHICLE BUILD DATES.
SUBJECT: Pop/Tick Sound In Steering Wheel Area
OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in
the steering column upper tilt head.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
2001 - 2002 (RG) Chrysler Voyager (International Markets)
1999 - 2002 (WJ) Grand Cherokee
2001 - 2002 (WG) Grand Cherokee (International Markets)
NOTE:
**This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before
Jan. 13, 2002 (MDH 0113XX).**
NOTE:
**For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7,
2003.**
SYMPTOM/CONDITION:
A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion.
The sound is associated with input from the road surface. It may be difficult to readily repeat the
sound once it has occurred until additional road input is experienced, such as driving over an
expansion strip.
DIAGNOSIS:
If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure.
NOTE:
If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99
(Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this
bulletin.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area > Page 6625
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Repair Procedure
1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before
beginning steering wheel removal procedure.
WARNING:
Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to
disable the air bag system. Failure to do this could result in accidental air bag deployment and
possible personal injury.
2. Remove and isolate the negative battery cable from the battery.
3. Remove the lower and upper steering column shrouds.
4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control
(if equipped), and radio control (if equipped) wiring connections.
5. Remove the steering wheel attaching nut.
6. Using the appropriate steering wheel puller, remove the steering wheel.
7. Remove the multi-function switch and its wiring connections.
8. Disconnect the clock spring wiring connection and remove the clock spring.
NOTE:
When removing the clock spring, do not change the orientation of the clock spring inner wheel. If
the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered.
Follow the procedure for clock spring centering in the appropriate service manual.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area > Page 6626
9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly.
10. Remove the snap ring from the steering shaft upper tilt head assembly.
11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing.
12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column.
13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering
column.
14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing
wedge.
15. Remove and discard the wave washer.
16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing
wedge (Fig. 1).
17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or
equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.).
18. Install the upper bearing wedge to the tilt steering shaft.
19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring
groove. This will facilitate snap ring installation.
20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the
steering shaft outward and push the snap ring as far down the shaft as possible.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > Customer Interest for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 > Steering
Column - Pop/Tick From Steering Wheel Area > Page 6627
21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering
shaft so the one edge of the tool is resting on the snap ring (Fig. 2).
22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool
05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into
its groove on the steering shaft.
NOTE:
Do not over torque steering wheel nut.
NOTE:
Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool
05083385AA can be discarded.
23. Make sure that the snap ring is fully seated into its groove.
24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive
to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.).
25. Install the clock spring and its wiring connections.
26. Install the multi-function switch and its wiring connections.
27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.).
28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring
connections.
29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.).
30. Install the lower and upper steering column shrouds.
31. Connect negative battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area
Technical Service Bulletin # 19-003-03 Date: 030829
Steering Column - Pop/Tick From Steering Wheel Area
NUMBER: 19-003-03
GROUP: Steering
DATE: Aug. 29, 2003
THIS BULLETIN SUPERSEDES SERVICE BULLETIN 19-008-01, DATED NOV. 23, 2001, WHICH
SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH
**ASTERISKS**. THE REVISION INCLUDES AN ADDED NOTE AND A REVISED NOTE
CORRECTING VEHICLE BUILD DATES.
SUBJECT: Pop/Tick Sound In Steering Wheel Area
OVERVIEW: This bulletin involves installing a shim package and a tilt head housing assembly in
the steering column upper tilt head.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
2001 - 2002 (RG) Chrysler Voyager (International Markets)
1999 - 2002 (WJ) Grand Cherokee
2001 - 2002 (WG) Grand Cherokee (International Markets)
NOTE:
**This bulletin applies to vehicles equipped with tilt steering (sales code SUA) built on or before
Jan. 13, 2002 (MDH 0113XX).**
NOTE:
**For vehicles built on or after Jan. 14, 2002 refer to service bulletin 19-001-03 dated Feb. 7,
2003.**
SYMPTOM/CONDITION:
A pop/tick sound may be heard coming from the steering wheel area while the vehicle is in motion.
The sound is associated with input from the road surface. It may be difficult to readily repeat the
sound once it has occurred until additional road input is experienced, such as driving over an
expansion strip.
DIAGNOSIS:
If the vehicle exhibits the Symptom/Condition, perform the Repair Procedure.
NOTE:
If the symptom is experienced on 1996 - 2000 NS or GS vehicles, Service Bulletin (SB) 19-09-99
(Click/Rattle Sound in Area of Steering Wheel) should be performed in conjunction with this
bulletin.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area > Page 6633
PARTS REQUIRED:
EQUIPMENT REQUIRED:
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Repair Procedure
1. Make sure the front wheels of the vehicle are in the STRAIGHT AHEAD position before
beginning steering wheel removal procedure.
WARNING:
Remove and isolate the negative battery cable from the vehicle battery. This is the only sure way to
disable the air bag system. Failure to do this could result in accidental air bag deployment and
possible personal injury.
2. Remove and isolate the negative battery cable from the battery.
3. Remove the lower and upper steering column shrouds.
4. Remove the driver's air bag from the steering wheel. Disconnect the clock spring, speed control
(if equipped), and radio control (if equipped) wiring connections.
5. Remove the steering wheel attaching nut.
6. Using the appropriate steering wheel puller, remove the steering wheel.
7. Remove the multi-function switch and its wiring connections.
8. Disconnect the clock spring wiring connection and remove the clock spring.
NOTE:
When removing the clock spring, do not change the orientation of the clock spring inner wheel. If
the orientation of the clock spring inner wheel is changed, the clock spring will have to be centered.
Follow the procedure for clock spring centering in the appropriate service manual.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area > Page 6634
9. Using needle nose pliers, remove both tilt head return springs from the tilt head assembly.
10. Remove the snap ring from the steering shaft upper tilt head assembly.
11. Remove the two # 25 torx bit screws attaching the tilt rack to the tilt head housing.
12. Remove the two # 45 torx bit screws attaching the tilt head assembly to the steering column.
13. Lift tilt steering column lever and remove the tilt head housing and the tilt rack from the steering
column.
14. Remove the tilt head housing from the shaft being careful not to misplace the lower bearing
wedge.
15. Remove and discard the wave washer.
16. To the base of the shaft, install in order: the shim, the wave washer, and the lower bearing
wedge (Fig. 1).
17. Install the new tilt head assembly to the steering shaft. Apply Mopar Lock & Seal adhesive (or
equivalent) to both torx screw threads only and tighten to 11 N.m (100 in. lbs.).
18. Install the upper bearing wedge to the tilt steering shaft.
19. Apply a light coat of Mopar silicon spray lubricant on the steering shaft near the snap ring
groove. This will facilitate snap ring installation.
20. Position the new snap ring onto the shaft near the bearing wedge. With one hand, pull the
steering shaft outward and push the snap ring as far down the shaft as possible.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Column > Tilt Wheel Pivot > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Tilt Wheel Pivot: > 19-003-03 > Aug > 03 >
Steering Column - Pop/Tick From Steering Wheel Area > Page 6635
21. From the parts package, use special tool 05083385AA (Installer) and place it over the steering
shaft so the one edge of the tool is resting on the snap ring (Fig. 2).
22. Thread the steering wheel nut onto the steering shaft and against the edge of Special Tool
05083385AA. Tighten the steering wheel nut to 16 N.m (12 ft. lbs.) This will slide the snap ring into
its groove on the steering shaft.
NOTE:
Do not over torque steering wheel nut.
NOTE:
Make sure the snap ring is fully seated into its groove. Once the repair is complete, tool
05083385AA can be discarded.
23. Make sure that the snap ring is fully seated into its groove.
24. Lift the tilt lever and slide the tilt head rack into position. Apply Mopar Lock and Seal adhesive
to the torx screw threads and install the torx screws and tighten to 6 N.m (50 in. lbs.).
25. Install the clock spring and its wiring connections.
26. Install the multi-function switch and its wiring connections.
27. Install the steering wheel and tighten steering wheel nut to 61 N.m (45 ft. lbs.).
28. Connect the clock spring, speed control (if equipped), and radio control (if equipped) wiring
connections.
29. Install driver's air bag and tighten screws to 10 N.m (90 in. lbs.).
30. Install the lower and upper steering column shrouds.
31. Connect negative battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 6644
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 6645
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 6646
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 6647
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 6648
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Customer Interest: > 19-05-98 > Aug > 98 > Power Steering - Honk Or Squeal Noise at Low Speed >
Page 6649
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed
Technical Service Bulletin # 19-05-98 Date: 980828
Power Steering - Honk Or Squeal Noise at Low Speed
NO: 19-05-98
GROUP: Steering
DATE: Aug. 28, 1998
SUBJECT: "Honk" Or Squeal Noise During Parking Lot Maneuvers
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETINS 19-07-97, DATED MAY 9,
1997 AND 19-11-97, DATED DEC. 5, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES
AND NOTED IN THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004).
REVISIONS INCLUDE ADDITIONAL MODELS, ADDITIONAL SYMPTOM/CONDITION, AND
REVISED DIAGNOSIS AND REPAIR PROCEDURES. **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
MODELS: 1996 - **1999** (NS) Town & Country/Caravan/Voyager 1996 - **1999** (GS) Chrysler
Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE VEHICLES.
SYMPTOM/CONDITION:
**SYMPTOM ONE:
"Honk" noise, which may also be described by vehicle operator as an intermittent groan or squawk
noise, heard during stationary or low speed parking lot maneuvers, the duration is usually less than
one second. The noise usually occurs near the ends of steering travel when reversing direction.
This noise condition typically does not develop until the vehicle has accumulated at least a few
hundred miles.
SYMPTOM TWO:
A high pitched squeal lasting up to a couple of seconds which occurs when returning the steering
wheel to center from near the end of travel. This condition can occur on a new vehicle or one with
little or no mileage after service.
Two other potential steering system issues which are not covered under this bulletin are steering
moan and steering shudder. Steering moan, unlike honk, is normally sustained throughout the
entire steering range and usually related to power steering line grounding, air in the steering
system due to leaks, or power steering pump performance. It may or may not be present at all
temperatures. Steering shudder is a vehicle vibration which usually occurs during stationary
steering and may also be temperature dependent. Vehicles should be expected to have increased
shudder after servicing the steering system. Several hundred customer miles may be required to
stabilize the system. **
DIAGNOSIS:
**If the vehicle operator describes either of the above Symptoms/Conditions, perform the Repair
Procedure. Limited steering evaluations by service technicians to familiarize themselves with the
issue should be performed, but prolonged evaluation of the steering system could result in
overheating of the system resulting in incorrect diagnosis and system damage.**
PARTS REQUIRED:
1 05011872AA Line, Power Steering Pressure
1 05011873AA Line, Power Steering Return
1 04883077 Fluid, Power Steering
2 04546098 Clip, Line
1 04641780 Strap, Tie
1 06035824 Clamp, Hose
AR (1) 04874878AB Gear, Power Steering
AR (1) 06504585 Bolt, Power Steering Gear Left Side Attaching
AR (1) 06032839 Clamp
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 6655
19-50-17-90 P/S Hose Replacement 0.4 Hrs.
19-00-02-92 Steering Gear Replacement 2.3 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
NOTE:
THE REPAIR PROCEDURE IS A COMPLETE REVISION AND NO **ASTERISKS** HAVE BEEN
USED TO HIGHLIGHTS REVISIONS.
This bulletin involves installing revised power steering pressure and return lines and/or power
steering gear.
WARNING:
POWER STEERING OIL, ENGINE PARTS AND THE EXHAUST SYSTEM MAY BE EXTREMELY
HOT IF THE ENGINE HAS BEEN RUNNING. DO NOT START THE ENGINE WITH ANY LOOSE
OR DISCONNECTED LINES. DO NOT ALLOW LINES TO TOUCH HOT EXHAUST MANIFOLD
OR CATALYST.
NOTE:
IF REVISED POWER STEERING LINES HAVE BEEN INSTALLED PREVIOUSLY OR IF THE
VEHICLE IS EQUIPPED WITH A 2.4L ENGINE, SKIP TO THE STEERING GEAR
REPLACEMENT PROCEDURE IN THIS BULLETIN.
1. Wipe the power steering fluid reservoir cap and area around it free of dirt. Remove the power
steering fluid reservoir cap.
2. Use a siphon pump to remove as much fluid as possible from the power steering fluid reservoir.
3. Raise the vehicle on an appropriate hoist.
4. Move the heat sleeve on the power steering fluid return line to expose the return line to steel
tube connection. Remove the hose clamp from the power steering fluid return line (Figure 1).
5. Obtain a drain pan and remove the power steering fluid return line from the steel tube and allow
the power steering fluid to drain into the pan.
6. Remove the bolt attaching the power steering line routing bracket to the front suspension cradle.
Save the bracket and fastener for reuse.
7. Remove the power steering fluid return line screw clamp & hose from the power steering pump
return line fitting and the power steering fluid return line tube from the steering gear (Figure 2).
Discard the line and screw clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 6656
8. Remove the power steering fluid pressure line from the power steering pump pressure fitting
(Figure 3).
9. Disconnect the power steering pressure line from the power steering gear assembly (Figure 2).
Remove and discard the power steering pressure line.
10. Loosely install the revised power steering pressure line, p/n 05011872AA and the revised
power steering return line, p/n 05011873AA fittings to the steering gear.
NOTE:
DO NOT TORQUE THE POWER STEERING LINE FITTINGS TO THE STEERING GEAR PRIOR
TO INSTALLING THE BRACKET THAT SECURES THE LINES TO THE FRONT SUSPENSION
CRADLE AND THE CLIPS THAT SEPARATE THE LINE, (FIGURE 4). DO NOT ALLOW
TWISTING OF THE RUBBER PORTION (PROTECTED BY CONVOLUTE TUBING) OF THE
POWER STEERING RETURN LINE.
11. Route the power steering pressure line so it is over top of the power steering pump return tube
and loosely install the power steering pressure line fitting to the power steering pump.
12. Install the bracket removed in step 6 around both the power steering pressure and return lines.
Attach the bracket to the front suspension cradle with the original bolt so the slotted hole side of the
bracket is against the front suspension cradle. Orient the bracket so the bolt is in the 1 to 2 o'clock
position when viewed from the rear of the vehicle (Figure 4). Torque the bolt to 16 Nm (150 in.
lbs.).
13. Use clips, p/n 04546098, to clip the power steering pressure and return lines together just left of
the bracket attaching the power steering lines to the front suspension cradle and just to the right of
the convoluted tubing on the return line (Figure 4).
14. Place screw clamp, p/n 06035824, over the power steering return line hose end and push the
hose end of the power steering return line onto the power steering pump return fitting. Position the
clamp between the bead on the pump fitting and the end of the hose, then torque the clamp screw
to 2 Nm (18 in. lbs.).
15. Slide the heat sleeving on the power steering return line over the clamp and hose, secure the
sleeving position with tie strap p/n 04641780. Trim tie strap excess to prevent contact with
surrounding components.
16. Rotate the power steering pressure line until it is against the power steering pump return fitting
and hose. Torque the power steering pressure line fitting to 27-35 Nm (240-310 in. lbs.)
17. Torque the power steering line fittings to the power steering gear (Figure 2) to 27- 35 Nm
(240-310 in. lbs.).
18. POWER STEERING FLUID LEVEL ADJUSTMENT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 6657
NOTE:
DO NOT USE AUTOMATIC TRANSMISSION FLUID.
a. Add P/S fluid, p/n 04318085, to bring the fluid level in the reservoir to the "Full Cold" mark
(ambient temperature 21-27°C (70-80°F) and let the fluid settle for at least 2 minutes.
b. Start the engine and let it run for 10 seconds and turn it off.
c. Check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full Cold" mark if necessary
and let the fluid settle for at least 2 minutes.
d. Raise the front wheels off the ground.
e. Start the engine. Slowly turn the steering wheel right and left, until lightly touching the full turn
stops.
f. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
g. Lower the vehicle and start the engine. Slowly turn the steering wheel lock to lock.
h. Turn off the engine and check the P/S fluid level in the reservoir. Add fluid to bring it to the "Full
Cold" mark if necessary.
i. If the fluid is extremely foamy, do not run the engine for 10 minutes and repeat steps a through h.
NOTE:
STEERING SHUDDER CAN BE EXPECTED IMMEDIATELY AFTER FLUID FILL AND WILL
LESSEN CONSIDERABLY WITH ADDED MILEAGE.
19. After performing the power steering fluid level adjustment procedure and verifying no system
leaks, place the vehicle in drive with the brakes applied and steer the vehicle from stop to stop 50
times. Do not hold the vehicle at the steering stops or exceed 60 cycles as overheating could
occur. If no honk noise is heard. the Repair Procedure is complete. If either type of honk noise
occurs, replace the steering gear using the following procedure:
Steering Gear Replacement Procedure
1. With the front wheels centered, turn the ignition switch to the locked position and remove the key
from the switch. Turn the steering wheel to the left until the steering wheel security lock engages
(180°). This step ensures the clock spring will not be over extended.
2. With the vehicle on the ground, remove the black trim cover at the lower left side of the
instrument panel to gain access to the steering column shaft coupler. Disconnect the steering
column shaft coupler from the steering gear intermediate coupler (Figure 5).
3. Raise the vehicle on an appropriate hoist and remove both front tire and wheel assemblies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 6658
4. Push back the insulating wrap on the P/S return hose to expose the return hose to steel tube
connection and disconnect the hose from the tube (Figure 6). Allow the P/S fluid to drain then
dispose of the fluid properly.
5. Remove the nut attaching the outer tie rod end to the steering knuckle by holding the tie rod end
stud stationary with an 11/32 in. socket while turning the nut with a wrench (Figure 7). Repeat for
the other side.
6. Remove both of the tie rod ends from the steering knuckles using Special Tool MB-990635 or
MB-991113 (Figure 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 6659
7. Remove the 2 bolts and loosen the third that attach the Antilock Brake System (ABS) Hydraulic
Control Unit (HCU) to the front suspension cradle, as shown in Figure 9. Then rotate the HCU
rearward to allow access to cradle plate attaching nut and bolt just forward of the HCU.
8. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Separate the cradle plate from the vehicle.
9. Using an 18 mm crowfoot, remove both P/S fluid lines from the steering gear (Figure 10).
10. Remove the 3 bolts and nuts attaching the steering gear to the front suspension cradle and
lower the steering gear enough to allow access to the intermediate coupler roll pin.
11. Install Special Tool 6381 A through the center of the roll pin and secure the tool with the
knurled nut (Figure 11). Hold the threaded rod stationary while turning the nut to pull the roll pin out
of the intermediate coupler. Remove the special tool from the intermediate coupler.
12. Separate the intermediate coupler from the steering gear shaft and remove the steering gear
from the vehicle.
13. Position the revised steering gear (P/N 4874878) into the front suspension cradle, leaving room
to install the intermediate coupler.
14. Start the roll pin into the intermediate coupler by tapping it with an appropriate hammer, then
install the intermediate coupler onto the shaft of the steering gear.
15. Install Special Tool 6381A through the center of the roll pin and secure the tool with the knurled
nut (Figure 11). Hold the threaded rod stationary while turning the nut to push the roll pin into the
intermediate coupler. Remove the special tool from the intermediate coupler.
16. Attach the steering gear to the front suspension cradle with the 2 right side mounting bolts
removed in step 10, revised left side bolt (P/N 6504585), and 3 three nuts removed in step 10.
Torque the bolts/nuts to 183 Nm (135 ft. lbs.).
17. Attach the P/S fluid lines to the proper fitting on the steering gear (Figure 9). Torque the P/S
fluid line tube nuts to 31 Nm (275 in.lbs.).
18. Install the tie rod end into the steering knuckle and install the attaching nut onto the stud of the
tie rod end finger tight. Hold the tie rod end stud stationary with an 11/32 in. socket and torque the
nut with a crowfoot to 54 Nm (40 ft. lbs.). Repeat for the other side.
19. Attach the cradle plate to the front suspension cradle using the 10 bolts/nuts removed in step 8.
Torque the bolts/nuts to 165 Nm (123 ft. lbs.).
20. Position a gear type clamp (P/N 6032839) over the P/S fluid return hose and push the hose
onto the steel tube portion of the return line. Be sure the hose and clamp are positioned past the
upset bead on the steel tube and torque the clamp to 1.5-2.5 Nm (14-22 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 19-05-98 > Aug > 98 > Power Steering - Honk Or
Squeal Noise at Low Speed > Page 6660
21. Install front tire and wheel assemblies. Torque lug nuts to 129 Nm (95 ft. lbs.).
22. Lower the vehicle to a level where the interior of the vehicle is accessible, but the tires are still
off the ground.
23. Starting with the front wheels of the vehicle centered straight ahead, use the intermediate
coupler to turn the front wheels to the left until the intermediate coupler shaft is properly aligned
with the steering column coupler and assemble the couplers together.
24. Lower the vehicle so its full weight is resting on the ground.
25. Install the steering column coupler intermediate shaft retaining pinch bolt/nut and torque them
to 28 Nm (250 in. lbs.). Install the safety pin.
26. P/S fluid level adjustment, use the procedure outline, step 18.
27. FRONT TOE IN ADJUSTMENT
a. Ensure all tires are the same size and inflated to the recommended pressure.
b. Verify vehicle ride height is within specification (Figure 12).
c. Ensure the fuel tank is full and the vehicle is on a level surface
d. Center the steering wheel and lock in place with a steering wheel clamp.
NOTE:
DO NOT TWIST THE FRONT INNER TIE ROD TO STEERING GEAR RUBBER BOOTS DURING
FRONT WHEEL TOE IN ADJUSTMENT.
e. Loosen the front inner to outer tie rod end jam nut on both sides. Grasp the inner tie rods at their
serrations and rotate then to set the individual front toe into +0.05° and total front toe into +0.10°.
f. Torque the tie rod jam nuts to 75 Nm (55 ft. lbs.).
g. Adjust the steering gear tie rod boots so they are not stressed.
h. Remove the steering wheel clamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions
Steering Gear: All Technical Service Bulletins Steering - Steering Gear R & I Revisions
NUMBER: 26-08-98
GROUP: Miscellaneous
DATE: August, 1998
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Caravan/Voyager/Town & Country Service Manual - Publication Number
81-370-8105
DESCRIPTION OF CHANGES
Revision to the steering gear removal and Installation procedures
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions > Page 6665
19-29
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions > Page 6666
19-30
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions > Page 6667
19-31
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions
Steering Gear: All Technical Service Bulletins Steering - Steering Gear R & I Revisions
NUMBER: 26-08-98
GROUP: Miscellaneous
DATE: August, 1998
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Caravan/Voyager/Town & Country Service Manual - Publication Number
81-370-8105
DESCRIPTION OF CHANGES
Revision to the steering gear removal and Installation procedures
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions > Page 6673
19-29
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions > Page 6674
19-30
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > All Other Service Bulletins for Steering Gear: > 26-08-98 > Aug > 98 > Steering - Steering Gear R & I
Revisions > Page 6675
19-31
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 6676
Steering Gear: Specifications
To Cradle Attaching Bolts ....................................................................................................................
................................................ 183 Nm (135 ft. lbs.) Coupler Pinch Bolt ............................................
.................................................................................................................................. 28 Nm (250 inch
lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 6677
Steering Gear: Description and Operation
NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear should be replaced.
If a steering gear boot needs to be replaced due to damage, refer to Tie Rod Boot for proper
procedure.
The power steering system consists of these four major components. Power Steering Gear, Power
Steering Pump, Pressure Hose, and Return Line. Turning of the steering wheel is converted into
linear travel through the meshing of the helical pinion teeth with the rack teeth. Power assist
steering is provided by an open center, rotary type control valve which directs oil from the pump to
either side of the integral rack piston.
Road feel is controlled by the diameter of a torsion bar which initially steers the vehicle. As required
steering effort increases, as in a turn, the torsion bar twists, causing relative rotary motion between
the rotary valve body and the valve spool. This movement directs oil behind the integral rack
piston, which, in turn, builds up hydraulic pressure and assists in the turning effort.
The drive tangs on the pinion mate loosely with a stub shaft to permit manual steering control to be
maintained if the drive belt on the power steering pump should break. However, under these
conditions, steering effort will be increased.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Technical
Service Bulletins > Page 6678
Steering Gear: Testing and Inspection
GENERAL INFORMATION
The following procedure can be used to test the operation of the power steering system on this
vehicle. This test will provide the flow rate for the power steering system along with the maximum
relief pressure of the power steering pump. This test is to be performed any time a power steering
system problem is present to determine if the power steering pump or power steering gear is not
functioning properly. The following pressure and flow test is performed using Pressure/Flow Tester,
Special Tool 6815, or equivalent.
FLOW AND PRESSURE TEST PROCEDURE
1. Check power steering pump drive belt tension and adjust as necessary. 2. Disconnect power
steering fluid pressure hose, at power steering pump. Use a container for dripping fluid. 3. Connect
Pressure Gauge, Special Tool from kit 6815, or equivalent to both hoses using adapter fittings.
Connect spare pressure hose, to power
steering pump pressure hose fitting.
4. Completely open valve on Special Tool 6815, or equivalent. 5. Start engine and let idle long
enough to circulate power steering fluid through flow/pressure test and get air out of fluid. Then
shut off engine. 6. Check power steering fluid level, and add fluid as necessary. Start engine again
and let idle. 7. Pressure gauge should read below 862 kPa (125 psi), if above, inspect the hoses for
restrictions and repair as necessary. The initial pressure
reading should be in the range of 345 - 552 kPa (50 - 80 psi). The flow meter should read between
1.3 and 1.9 GPM.
CAUTION: The following test procedure involves testing power steering pump maximum pressure
output and flow control valve operation. Do not leave valve closed for more than 5 seconds as the
pump could be damaged.
8. Close valve fully three times and record highest pressure indicated each time. All three readings
must be within the specifications and within 345
kPa (50 psi) of each other.
NOTE: Power steering pump maximum relief pressure is 9653 to 10342 kPa (1400 to 1500 psi.). If power steering pump pressures are within specifications but not within 345 kPa (50 psi) of each
other, then replace power steering pump.
- If pressures are within 345 kPa (50 psi) of each other but below specifications, then replace
power steering pump.
CAUTION: Do not force the pump to operate against the stops for more than 5 seconds at a time
because, pump damage will result.
9. Open test valve. Turn steering wheel to the extreme left and right positions until against the
stops, recording the highest indicated pressure at each
position. Compare pressure gauge readings to power steering pump specifications. If highest
output pressures are not the same against either stop, the steering gear is leaking internally and
must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal
Steering Gear: Service and Repair Removal
The content of this article reflects changes called for in TSB 26-08-98.
NOTE: The power steering gear should NOT be serviced or adjusted. If a malfunction or oil leak
occurs, the complete steering gear assembly must be replaced.
CAUTION: Positioning the steering column in the locked position will prevent the clockspring from
being accidentally over-extended when the steering column is disconnected from the intermediate
steering coupler.
1. Remove cap from power steering fluid reservoir. 2. Using a siphon pump, remove as much
power steering fluid as possible from the power steering fluid reservoir. 3. With the ignition key in
the locked position turn the steering wheel to the left until the steering wheel is in the locked
position.
4. With the vehicle on the ground, disconnect the steering column shaft coupler from the steering
gear intermediate coupler. 5. Raise vehicle on jack stands or centered on a frame contact type
hoist. 6. Remove the front tires.
7. Raise the heat sleeve on the power steering return hose to expose the return hose to steel tube
connection. Remove the return hose from the metal
tube of the power steering fluid return line. Then allow the remaining power steering fluid to drain
from the system through the hose and metal tube.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6681
8. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with wrench.
Tie Rod End Removal From Steering Knuckle Arm
9. Remove both tie rod ends from steering knuckles, using Puller Special Tool MB-990635 or
MB-991113, or equivalents.
HCU To Suspension Cradle Mounting Bolts
10. Remove the 2 bolts and loosen the third attaching the antilock brakes Hydraulic Control Unit
(HCU) to the front suspension cradle. Then rotate
the HCU rearward to allow access to the cradle plate attaching nut and bolt just forward of the
HCU.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6682
Front Suspension Cradle Plate And Attaching Bolts
11. Remove the 10 nuts and bolts attaching the cradle plate to the bottom of the front suspension
cradle. Then remove the cradle plate from the cradle.
12. If the vehicle is equipped with All-Wheel-Drive, remove the power transfer unit.
13. Remove the bracket attaching the power steering fluid tubes to the front suspension cradle.
14. Using a 18 mm crowfoot, remove the power steering fluid pressure and return lines from the
power steering gear.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6683
15. Remove the 3 bolts and nuts mounting the steering gear to the front suspension cradle.
NOTE: The next step must be done to allow the removal of the steering gear from the front
suspension cradle. The steering gear can not be removed from the vehicle with the intermediate
coupler attached to the steering gear.
16. Lower steering gear from suspension cradle enough to allow access to the intermediate coupler
roll pin. Install Remover/Installer Special Tool
6831A, or equivalent through the center of the roll pin, securing with the knurled nut. Hold threaded
rod stationary while turning nut, this will pull the roll pin out of the intermediate coupler.
17. Separate the intermediate coupler from the shaft of the steering gear. 18. Remove the steering
gear assembly from the front suspension cradle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6684
Steering Gear: Service and Repair Installation
The content of this article reflects changes called for in TSB 26-08-98.
1. Install the steering gear up in the front suspension cradle, leaving room to install intermediate
coupler. 2. Start the roll pin into the intermediate coupler before installing coupler on steering gear
shaft. Start roll pin into coupler, using a hammer and
tapping it into the coupler. Then install the intermediate coupler on the shaft of the steering gear.
3. Install Remover/Installer Special Tool 6831A, or equivalent through the center of the roll pin,
securing it with the knurled nut. Hold threaded rod
stationary while turning nut, this will pull the roll pin into the intermediate coupler.
4. Install steering gear assembly on the front suspension cradle. Install the 3 steering gear to front
suspension cradle mounting bolts and nuts.
CAUTION: Proper torque on the steering gear to suspension cradle mounting bolts is very
important.
5. Tighten the 3 steering gear to suspension cradle mounting bolts to a torque of 183 Nm (135 ft.
lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6685
6. Attach the power steering fluid pressure and return lines to the proper fittings on the steering
gear. Tighten the power steering fluid line tube nuts
to a torque of 31 Nm (275 inch lbs.).
7. Install tie rod end into steering knuckle. Start tie rod end to steering knuckle attaching nut onto
stud of tie rod end. While holding stud of tie rod
end stationary using a 11/32 socket, tighten tie rod end to steering knuckle attaching nut. Then
using a crowfoot and 11/32 socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft.
lbs.).
8. If the vehicle is equipped with All-Wheel-Drive, install the Ppower transfer unit.
CAUTION: Proper torque on the cradle plate to suspension cradle mounting bolts is very important.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6686
Front Suspension Cradle Plate And Attaching Bolts
9. Install cradle plate on front suspension cradle and then install the 10 cradle plate to cradle
attaching bolts. Tighten the 9 M-14 attaching bolts to a
torque of 165 Nm (123 ft. lbs.). Tighten the 1 M-12 attaching bolt to a torque of 108 Nm (80 ft. lbs.).
10. Install the bracket attaching the power steering fluid tubes to the front suspension cradle.
11. Install the power steering fluid return hose on the steel tube at the front suspension cradle. 12.
Install a screw type hose clamp on the power steering hose to steel tube connection. Be sure hose
clamp is installed on return tube past the upset
bead on the tube. Tighten the screw clamp to a torque of 2 Nm (18 inch lbs.).
CAUTION: The protective heat shield sleeves must cover the entire rubber hose and hose to tube
connection portion of both the power steering
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Gear > Component Information > Service and
Repair > Removal > Page 6687
fluid pressure and return hoses. This is required to prevent the power steering hoses from being
overheated.
13. When used, properly position the protective heat sleeves on the power steering hoses. Then,
tie strap the heat sleeves to the power steering hoses
to keep them in their proper position.
14. Install the front tire and wheel assemblies on vehicle. Install the wheel lug nuts and torque to
129 Nm (95 ft. lbs.). 15. Lower the vehicle to a level were the interior of vehicle is accessible.
16. Using the intermediate coupler, turn the front wheels of the vehicle to the left until the
intermediate coupler shaft is properly aligned with the
steering column coupler. Assemble the steering column shaft coupler onto the steering gear
intermediate coupler. Install steering column coupler to intermediate shaft retaining pinch bolt.
Tighten the pinch bolt nut to a torque of 28 Nm (250 inch lbs.).
CAUTION: Do not use automatic transmission fluid in the power steering system. Only use Mopar
(R), Power Steering Fluid or an exact equivalent product.
17. Fill power steering pump fluid reservoir to the proper level. 18. Start the engine and let run for a
few seconds. Then turn the engine off. 19. Add fluid if necessary. Repeat the above procedure until
the fluid level remains constant after running the engine. 20. Raise front wheels of vehicle off the
ground. 21. Start the engine. Slowly turn the steering wheel right and left, lightly contacting the
wheel stops. Then turn the engine off. 22. Add power steering fluid if necessary. 23. Lower the
vehicle and turn the steering wheel slowly from lock to lock. 24. Stop the engine. Check the fluid
level and refill as required. 25. If the fluid is extremely foamy, allow the vehicle to stand a few
minutes and repeat the above procedure. 26. Fill power steering reservoir to correct level with
Mopar (R) Power Steering Fluid, or equivalent. 27. Adjust toe.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Shaft > Component Information > Tools and
Equipment
Special Tool 6831A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Steering Wheel > Component Information >
Specifications
Steering Wheel: Specifications
Retaining Nut .......................................................................................................................................
..................................................... 61 Nm (45 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information >
Service and Repair
Tie Rod Boot: Service and Repair
NOTE: The removal and installation of the inner tie rod boot must be performed with the steering
gear assembly removed from the vehicle.
REMOVE
1. Loosen the inner to outer tie rod jam nut. Remove the outer tie rod from the inner tie rod.
2. Remove nut attaching the outer tie rod end to the steering knuckle. Nut is to be removed from tie
rod end using the following procedure, hold tie
rod end stud with an 11/32 socket, while loosening and removing nut with wrench.
Tie Rod End Removal From Steering Knuckle Arm
3. Remove the tie rod end from the steering knuckle using Remover, Special Tool MB-991113 or
MB-990635, or equivalent. 4. Remove jam nut from inner tie rod.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information >
Service and Repair > Page 6698
5. Using pliers expand tie rod boot, to inner tie rod clamp and remove from steering gear boot.
6. Remove inner tie rod boot to steering gear clamp.
NOTE: After removing inner boot clamps. Use a very small screwdriver to lift boot from its retaining
groove in steering gear. Then the boot can be removed from steering gear.
INSTALL
1. Install tie rod boot to steering gear clamp on tie rod boot. 2. Install tie rod boot and clamp on
inner tie rod. 3. Install tie rod boot over steering gear housing and onto the end of the breather
tube.
4. Crimp inner tie rod boot to steering gear clamp using Crimper, Special Tool C4975A, or
equivalent. When installing clamp, Special Tool
C4975A, or equivalent must have bottom bolt tightened until their is no gap between the 2 bars of
the tool.
5. Lubricate inner tie rod boot groove with silicone type lubricant, then install outer boot seal to
inner tie rod clamp. (Clamp will have to be loosened
for toe adjustment).
6. Install inner to outer tie rod jam nut on inner tie rod. 7. Install outer tie rod on inner tie rod. Do not
tighten jam nut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information >
Service and Repair > Page 6699
8. Install tie rod end into the steering knuckle Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie rod
end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and
11/32 socket, torque tie rod end attaching nut to 54 Nm (40 ft. lbs.).
CAUTION: During this procedure do not allow the steering gear boot to become twisted.
9. Make toe adjustment by turning inner tie rod.
10. Tighten the inner to outer tie rod jam nut to 75 Nm (55 ft. lbs.) torque. Lubricate tie rod boot
groove with silicone type lubricant, before installing
outer boot clamp, making sure boot is not twisted.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod Boot > Component Information >
Service and Repair > Page 6700
Special Tool C-4975A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Specifications
Tie Rod End: Specifications
Adjusting Sleeve Nut ...........................................................................................................................
..................................................... 75 Nm (55 ft. lbs.) To Steering Knuckle Nut ..................................
........................................................................................................................................ 61 Nm (45 ft.
lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Outer Tie Rod End
Tie Rod End: Service and Repair Outer Tie Rod End
REMOVAL
1. Loosen inner tie rod to outer tie rod jam nut.
2. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with wrench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Outer Tie Rod End > Page 6706
Tie Rod End Removal From Steering Knuckle Arm
3. Remove the tie rod end stud from steering knuckle arm, using Remover, Special Tool
MB-990635 or MB-991113, or equivalents. 4. Remove outer tie rod end from inner tie rod by
unthreading it from the inner tie rod.
INSTALLATION
1. Install outer tie rod onto inner tie rod. Make sure jam nut is on inner tie rod. 2. Do not tighten jam
nut.
3. Install tie rod end into the steering knuckle. Start tie rod end to steering knuckle attaching nut
onto stud of tie rod end. While holding stud of tie
rod end stationary, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and
11/32 socket, torque tie rod end attaching nut to 54 Nm (40 ft. lbs.).
CAUTION: During this procedure do not allow the steering gear boot to become twisted.
4. Adjust the front Toe setting on the vehicle. 5. Tighten tie rod jam nut to 55 Nm (75 ft. lbs.) torque.
6. Adjust the steering gear to inner tie rod boots at inner tie rod if they became twisted during Toe
adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Outer Tie Rod End > Page 6707
Tie Rod End: Service and Repair Inner Tie Rod End
The inner tie rod end is serviced with the rack and pinion assembly only. Chrysler does not provide
a separate service procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Steering > Tie Rod > Tie Rod End > Component Information >
Service and Repair > Page 6708
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description
and Operation
Ball Joint: Description and Operation
The ball joint is pressed into the lower control arm. The ball joint has a non-tapered stud with a
notch to provide clearance for the steering knuckle clamp bolt and to provide retention of the ball
stud in the steering knuckle. The ball joint stud is clamped and locked into the steering knuckle leg
using a pinch bolt. The ball joint used on this vehicle is replaceable and if found defective can be
serviced as a separate component of the lower control arm assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Description
and Operation > Page 6713
Ball Joint: Testing and Inspection
With the weight of the vehicle resting on the road wheels, grasp the grease fitting as shown and
with no mechanical assistance or added force attempt to rotate the grease fitting.
If the ball joint is worn the grease fitting will rotate easily. If movement is noted, replacement of the
ball joint is recommended.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension)
Ball Joint: Service and Repair Ball Joint Replacement (Front Suspension)
REMOVE
1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly.
2. Position receiving cup, Special Tool 6758, or equivalent to support lower control arm when
removing ball joint assembly. Install Remover,
Special Tool 6919, or equivalent on top of the ball joint assembly.
3. Using the arbor press, press the ball joint assembly completely out of the lower control arm.
INSTALL
NOTE: When installing ball joint in lower control arm, position the ball joint in control arm so notch
in ball joint stud is in the direction shown. This will ease assembly of the ball joint to the steering
when installing pinch bolt.
1. By hand, position ball joint into ball joint bore of lower control arm. Be sure ball joint is not
cocked in the bore of the control arm, this will cause
the ball joint to bind when being pressed into control arm.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 6716
2. Position control arm with installed ball joint, in an arbor press with Receiving Cup, Special Tool
6758, or equivalent supporting the lower control
arm. Then center Installer, Special Tool 6908-4, or equivalent on the bottom of the ball joint.
3. Carefully align all pieces. Then press the ball joint into the lower control arm until it is completely
seated against surface of lower control arm. The
ball joint is correctly installed when there is no gap between the ball joint and the lower control arm.
Do not apply excessive force against the ball joint or the lower control arm.
CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the
ball joint seal must be positioned as shown.
4. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown.
CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the
sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 6717
5. Place Installer, Special Tool 6758, or equivalent over seal boot and squarely align it with bottom
edge of seal boot. Apply hand pressure to Special
Tool 6758, or equivalent until seal boot is pressed squarely against top surface of lower control
arm.
CAUTIONS: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint using
Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but prior to
top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the seal boot
at notch when grease is pumped into ball joint, failure to do so will balloon and damage seal boot.
Do not over grease the ball joint, this will prevent the seal boot from pushing down on the stud of
the ball joint.
- After the ball joint is properly greased, clip the end of the grease fitting off below the hex. The ball
joint seal boot is non-purgeable and further greasing is not required and can result in damage to
the seal boot.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 6718
Ball Joint: Service and Repair Seal Boot Replacement
REMOVE
1. Using a screw driver or other suitable tool, pry the seal boot off of the ball joint assembly.
INSTALL
CAUTION: When installing the ball joint seal on the ball joint/lower control arm, the shield on the
ball joint seal must be positioned as shown.
1. Install a NEW seal boot by hand as far as possible on the ball joint. Installation of the seal boot is
to be with the shield positioned as shown.
CAUTION: Do not use an arbor press to install the sealing boot on the ball joint. Damage to the
sealing boot will occur if excessive pressure is applied to the sealing boot when it is being installed.
2. Place Installer, Special Tool 6758 over seal boot and squarely align it with bottom edge of seal
boot. Apply hand pressure to Special Tool 6758
until seal boot is pressed squarely against top surface of lower control arm.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Ball Joint Replacement (Front Suspension) > Page 6719
CAUTION: A replacement ball joint is not prelubricated. Properly lubricate the replacement ball joint
using Mopar Multi-Mile grease or an equivalent. Lubricate ball joint after seal boot is installed but
prior to top of seal boot being pushed down below notch in ball joint stud. Air must vent out of the
seal boot at notch when grease is pumped into ball joint, failure to do so will balloon and damage
seal boot. Do not over grease the ball joint, this will prevent the seal boot from pushing down on the
stud of the ball joint.
CAUTION: After the ball joint is properly greased, clip the end of the grease fitting off below the
hex. The ball joint seal boot is non-purgeable and further greasing is not required and can result in
damage to the seal boot.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Ball Joint > Component Information > Service and
Repair > Page 6720
Ball Joint: Tools and Equipment
Special Tool 6758
Special Tool 6919
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Testing and Inspection
Control Arm Bushing: Testing and Inspection
Inspect both control arm bushings for severe deterioration, and replace if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Front
Control Arm Bushing: Service and Repair Front
REMOVE
1. Remove the lower control arm from the front suspension cradle. 2. Securely mount the lower
control arm in a vise.
3. Assemble or removal of the front bushing, the Bushing Receiver, Special Tool 6908-2, Bushing
Remover, Special Tool 6908-1, Nut, Special Tool
6908-3 thrust washer, or equivalents, threaded rod and small nut, as shown on the lower control
arm and front bushing.
4. To remove front bushing from lower control arm, hold the threaded rod stationary and tighten the
Nut, Special Tool 6908-3, or equivalent. This
will force the front bushing out of the lower control arm and into Bushing Receiver, Special Tool
6908-2, or equivalent.
INSTALL
1. Securely mount the lower control arm in a vise.
NOTE: The lower control arm front bushing is a directional bushing. It must be installed in the lower
control arm positioned as shown.
2. Position the front bushing in the lower control arm so that the 2 rubber blocks on the bushing are
positioned horizontally as shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Front > Page 6727
3. Assemble for installation of the front bushing, the Bushing Receiver, Special Tool 6908-5,
Bushing Installer, Special Tool 6908-4, Nut, Special
Tool 6908-3 thrust washer, or equivalents, threaded rod and small nut, as shown on the lower
control arm and front bushing.
4. To install the front bushing in lower control arm, hold the threaded rod stationary and tighten the
Nut, Special Tool 6908-3, or equivalent. This
will pull the front bushing into the lower control arm.
5. Continue pulling the bushing into the lower control arm until bushing is seated squarely against
the lower control arm and there is no gap between
the bushing and the lower control arm.
6. Install the lower control arm on the front suspension cradle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Front > Page 6728
Control Arm Bushing: Service and Repair Rear
REMOVE
1. Remove the lower control arm from the front suspension cradle. 2. Mount the lower control arm
in a vise without using excessive clamping force.
3. Using a sharp knife, (such as a razor) slit the bushing lengthwise to allow its removal from the
lower control arm. 4. Remove the bushing from the lower control arm.
INSTALL
CAUTION: Do not apply grease or any other type of lubricant other than the silicone lubricant
specified below to the control arm bushing.
1. Apply Mopar Silicone Spray Lube or an equivalent, to the hole in lower control arm rear bushing.
This will aid in the installation of the bushing on
the lower control arm.
2. With the lower control arm held securely in a vise, install bushing on lower control arm. Install
bushing by pushing and rocking the bushing until it
is fully installed on lower control arm. Be sure when bushing is installed it is past the upset on the
end of the lower control arm.
3. The rear bushing of the lower control arm, when correctly installed, is to be positioned on the
lower control arm as shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Control Arm > Control Arm Bushing > Component
Information > Service and Repair > Page 6729
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Specifications
Cross-Member: Specifications
To Body Attaching Bolts ......................................................................................................................
................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12
............................................................................................................................................ 108 Nm
(80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14
.......................................................................................................................................... 166 Nm
(123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts
............................................................................................................................................... 165 Nm
(123 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Specifications > Page 6733
Cross-Member: Description and Operation
This vehicle uses a one piece cast aluminum cradle for the front suspension. The cradle is used as
the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has
the power steering hoses and the chassis brake tubes attached to it.
The cradle is mounted to the front frame rails at four points, two on each side of the vehicle. The
cradle is isolated from the body of the vehicle using four isolators, one located at each mounting
bolt location.
CAUTION: If a threaded hole in the suspension cradle needs to be repaired, only use the type of
thread insert and installation procedure specified for this application. The threaded holes in the
cradle that are used for attachment of the lower control arm rear bushing retainer, power steering
hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil
thread insert, or equivalent which has been specifically developed for this application.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Cross-Member > Component Information >
Specifications > Page 6734
Cross-Member: Service and Repair
CAUTION: When performing this procedure use only the thread inserts which are specified in the
Mopar (R) Parts Catalog, or equivalent for this repair procedure. These thread inserts have been
specifically developed for this application and use of other types of thread inserts can result in an
inferior long term repair.
SUSPENSION CRADLE THREAD REPAIR PROCEDURE
The threaded holes in the front suspension cradle, if damaged, can repaired by installing a
Heli-Coil (R) thread insert.
The threaded holes that are repairable using the thread insert, are the lower control arm rear
bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering
hoses, and brake hose attachment holes.
This repair procedure now allows the threaded holes in the suspension crossmember to be
repaired, eliminating the need to replace the crossmember if damage occurs to one of the threaded
holes.
The thread inserts for this application are specified by part number in the Mopar (R) Parts Catalog.
Do not use a substitute thread insert.
The specific tools and equipment required to install the thread insert are listed below. Refer to the
instructions included with the thread insert for the detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for the repair of M8 x 1.25 and M10 x 1.5 threads.
Be sure the correct tools are used for the required thread insert size.
TOOL REQUIREMENT FOR M8 x 1.25 THREAD
- 8.3 mm (5/16 inch) Drill Bit
- 120° Countersink
- Heli-Coil (R) Tap #4863-8
- Heli-Coil (R) Gage #4624-8
- Heli-Coil (R) Hand Inserting Tool 7751-8
- Needle Nose Pliers - For Removal Of Thread Insert Driving Tang
TOOL REQUIREMENT FOR M10 x 1.5 THREAD
- 10.5 mm (25/64 inch) Drill Bit
- 120° Countersink
- Heli-Coil (R) Tap #4863-10
- Heli-Coil (R) Gage #4624-10
- Heli-Coil (R) Hand Inserting Tool 7751-10
- Needle Nose Pliers - For Removal Of Thread Insert Driving Tang
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications
Front Steering Knuckle: Specifications
Ball Joint Stud To Steering Knuckle Nut/Bolt
..................................................................................................................................... 136 Nm (100
ft. lbs.) Wheel Stop ..............................................................................................................................
................................................................. 95 Nm (70 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 6738
Front Steering Knuckle: Service Precautions
CAUTION: The front suspension knuckle is not a repairable component of the vehicles front
suspension IT MUST BE REPLACED. If bent, broken or damaged in any way, do not attempt to
straighten or repair the steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Specifications > Page 6739
Front Steering Knuckle: Description and Operation
The steering knuckle is a single casting with legs machined for attachment of the strut damper,
steering linkage, disc brake caliper, and lower control arm ball joint. The steering knuckle also has
the front hub/bearing assembly mounted to it. The hub is positioned through the bearing and
knuckle, with the constant velocity stub shaft splined through the hub.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal
Front Steering Knuckle: Service and Repair Removal
1. Raise vehicle on jack stands or centered on a frame contact type hoist.
2. Remove the cotter pin and nut lock from the end of the stub axle. 3. Remove the wheel and tire
assembly from the vehicle.
4. Remove the wave washer from the end of the stub axle.
CAUTION: Wheel bearing damage will result if after loosening hub nut, vehicle is rolled on the
ground or the weight of the vehicle is allowed to be supported by the tires.
5. With the vehicle's brakes applied to keep hub from turning, loosen and remove the stub axle to
hub nut.
6. Remove the 2 front disc brake caliper to steering knuckle attaching bolts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6742
7. Remove the disc brake caliper from the steering knuckle. Caliper is removed by first rotating top
of caliper away from steering knuckle and then
removing bottom of caliper out from under machined abutment on steering knuckle.
8. Support disc brake caliper assembly by using a wire hook and suspending it from the strut
assembly. Do not allow the brake caliper assembly to
hang by the brake flex hose.
9. Remove the brake rotor from the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6743
10. Remove nut attaching outer tie rod end to steering knuckle. Nut is to be removed from tie rod
end using the following procedure, hold tie rod end
stud with a 11/32 socket while loosening and removing nut with a wrench.
Tie Rod End Removal From Steering Knuckle Arm
11. Remove the tie rod end from steering knuckle using Remover, Special Tool MB-991113, or
equivalent.
12. Remove the front wheel speed sensor from the steering knuckle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6744
13. If equipped, remove the wheel stop from the steering knuckle. When installing the pinch bolt
when assembling the steering knuckle to the ball joint
, the pinch bolt must be installed from the rear facing the front on the vehicle.
14. Remove the steering knuckle to ball joint stud, clamping nut and bolt from the steering knuckle.
15. Using a pry bar, separate steering knuckle from ball joint stud. Note: Use caution when
separating ball joint stud from steering knuckle, so ball
joint seal does not get cut.
NOTE: Care must be taken not to separate the inner C/V joint during this operation. Do not allow
driveshaft to hang by inner C/V joint after removing outer C/V Joint from the hub/bearing assembly
in steering knuckle, end of driveshaft must be supported.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6745
16. Pull steering knuckle assembly out and away from the outer C/V joint of the driveshaft
assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during removal. Remove nuts while holding bolts stationary in the steering knuckles.
17. Remove the 2 steering knuckle to strut damper clevis bracket attaching bolts. 18. Remove the
steering knuckle from the strut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6746
Front Steering Knuckle: Service and Repair Installation
1. Transfer, or install if necessary, a new hub/bearing assembly into the steering knuckle. Refer to
Transmission and Drivetrain.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
NOTE: If the vehicle being serviced is equipped with eccentric strut assembly attaching bolts, the
eccentric bolt must be installed in the bottom (slotted) hole on the strut clevis bracket.
2. Install steering knuckle back in clevis bracket of strut damper assembly. Install the strut damper
to steering knuckle attaching bolts. Tighten both
attaching bolts to a torque of 90 Nm (65 ft. lbs.) plus an additional 1/4 turn.
3. Slide drive shaft back into front hub and bearing assembly. Then install steering knuckle onto the
stud of the ball joint assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6747
4. Install a NEW steering knuckle to ball joint stud, clamping bolt and nut. Tighten the clamping bolt
and nut to a torque of 145 Nm (105 ft. lbs.).
5. Install tie rod end into steering knuckle. Start attaching nut onto stud of tie rod end. While holding
stud of tie rod end stationary using a 11/32
socket, tighten tie rod end to steering knuckle attaching nut. Then using a crowfoot and 11/32
socket, tighten the tie rod end attaching nut to a torque of 54 Nm (40 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6748
6. Install braking disc on hub and bearing assembly.
7. Install disc brake caliper assembly on steering knuckle. Caliper is installed by first sliding bottom
of caliper under abutment on steering knuckle,
and then rotating top of caliper against top abutment.
8. Install disc brake caliper assembly to steering knuckle attaching bolts. Tighten the disc brake
caliper assembly attaching bolts to a torque of 35 Nm
(30 ft. lbs.).
9. Clean all foreign matter from the threads of the outer C/V joint stub axle. Install the washer and
stub axle to hub/bearing assembly nut on stub axle
and securely tighten nut.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Front Steering Knuckle > Component Information >
Service and Repair > Removal > Page 6749
10. Install wheel speed sensor and mounting bolt on steering knuckle. Tighten the speed sensor
attaching bolt to a torque of 7 Nm (60 inch lbs.). 11. Install front wheel and tire assembly. Install
and tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to half the
required specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
12. Lower vehicle.
13. With the vehicle's brakes applied to keep hub from turning, tighten the hub nut to a torque of
203 Nm (150 ft. lbs.). 14. Install the spring wave washer on the end of the stub axle.
15. Install the hub nut lock, and a new cotter pin. Wrap cotter pin prongs tightly around the hub nut
lock as shown. 16. Set front Toe on vehicle to required specification.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Lateral Stabilizer Rod > Component Information >
Service and Repair
Lateral Stabilizer Rod: Service and Repair
REMOVE
1. Remove the nut and bolt mounting the track bar to the rear axle. 2. Remove the nut and bolt
attaching the track bar to the track bar mount on the body of the vehicle. Remove the track bar
from the track bar mount.
INSTALL
1. Install the track bar first into the body mount for the track bar. Install the track bar bolt with the
head of the bolt facing toward the rear of the
vehicle. Do not tighten.
2. Install the track bar into its mounting bracket on the rear axle. Install the track bar bolt with the
head of the bolt facing toward the rear of the
vehicle. Do not tighten.
3. Lower the vehicle to the ground until the full weight of the vehicle is supported by the wheels.
Tighten both track bar attaching bolts to a torque of
95 Nm (70 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Specifications
Stabilizer Bushing: Specifications
FRONT:
Bushing Retainer Attaching Bolts
......................................................................................................................................................... 70
Nm (50 ft. lbs.)
REAR:
Bushing Retainer Attaching Bolts
......................................................................................................................................................... 61
Nm (45 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Description and Operation > Front
Stabilizer Bushing: Description and Operation Front
Attachment of the stabilizer bar to the front suspension cradle is through 2 rubber-isolator bushings
and bushing retainers. The stabilizer bar to Mc Pherson strut assembly attachment is done utilizing
a sway bar attaching link. All parts of the stabilizer bar are serviceable, and the stabilizer bar to
crossmember bushings are split for easy removal and installation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Description and Operation > Front > Page 6759
Stabilizer Bushing: Description and Operation Rear
Attachment to the rear axle tube, and rear flame rails is through rubber-isolated bushings. All parts
are serviceable, and the stabilizer bar to axle bushings are split for easy removal and installation.
The split in the bushing should be positioned up when the stabilizer bar is installed on the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Bushing >
Component Information > Description and Operation > Page 6760
Stabilizer Bushing: Service and Repair
If stabilizer bar to front suspension cradle bushings require replacement at time of inspection install
new bushings before installing stabilizer bar. Stabilizer bar bushings are replaced by opening the
slit on the bushings and peeling them off the stabilizer bar. Install new bushings on stabilizer bar,
by spreading bushing at slit and forcing them on stabilizer bar.
NOTE: Bushings must be installed on stabilizer bar so the square corner of the bushing will be
down and slit in bushing will be facing the rear of the vehicle when the stabilizer is installed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front
Suspension - Knock/Squawk Sound
Stabilizer Link: Customer Interest Front Suspension - Knock/Squawk Sound
NUMBER: 02-004-01
GROUP: Suspension
DATE: July 6, 2001
SUBJECT: Knock/Squawk Sound From Front Suspension
OVERVIEW: This bulletin involves installing new front sway bar link assemblies.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Town & Country/Caravan/Voyager
2001 (RG) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low
speed turn such as a parking lot maneuver.
2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy
roads.
DIAGNOSIS:
1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel
in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway
bar link. Listen or feel for the condition described above while the wheel is being turned. If the
condition is present, perform the Repair Procedure.
2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an
appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any
loose, damaged or worn components and test drive vehicle. It the condition is still present, perform
the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Raise the vehicle on a frame contact hoist.
2. Remove both front wheels.
3. Remove the upper and lower sway bar link nuts and remove the sway bar link.
CAUTION:
WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW
THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING
A # 40 TORX BIT INTO THE END OF THE STUD.
4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.).
5. Perform steps 3 and 4 for the other sway bar link.
6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.)
and then use a criss-cross pattern again to tighten to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Customer Interest for Stabilizer Link: > 02-004-01 > Jul > 01 > Front
Suspension - Knock/Squawk Sound > Page 6769
a final torque of 135 N.m (100 ft. lbs.).
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul
> 01 > Front Suspension - Knock/Squawk Sound
Stabilizer Link: All Technical Service Bulletins Front Suspension - Knock/Squawk Sound
NUMBER: 02-004-01
GROUP: Suspension
DATE: July 6, 2001
SUBJECT: Knock/Squawk Sound From Front Suspension
OVERVIEW: This bulletin involves installing new front sway bar link assemblies.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
2001 (RS) Town & Country/Caravan/Voyager
2001 (RG) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
1. A squawk/creak/groan sound is heard when turning the steering wheel at a stop or during a low
speed turn such as a parking lot maneuver.
2. A knocking/clunking sound is heard from the front suspension while driving over rough/bumpy
roads.
DIAGNOSIS:
1. With a helper in the vehicle, apply the parking brake, start the engine and turn the steering wheel
in both directions. Reach between the top of the front tire and the wheel well lip and grasp the sway
bar link. Listen or feel for the condition described above while the wheel is being turned. If the
condition is present, perform the Repair Procedure.
2. Drive the vehicle over rough/bumpy roads to verify condition. Raise the vehicle on an
appropriate hoist and perform a visual inspection of the front suspension. Repair or replace any
loose, damaged or worn components and test drive vehicle. It the condition is still present, perform
the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE:
1. Raise the vehicle on a frame contact hoist.
2. Remove both front wheels.
3. Remove the upper and lower sway bar link nuts and remove the sway bar link.
CAUTION:
WHEN INSTALLING THE NUTS TO THE STUDS OF THE SWAY BAR LINKS, DO NOT ALLOW
THE STUD TO ROTATE IN ITS SOCKET. HOLD THE STUD FROM ROTATING BY INSERTING
A # 40 TORX BIT INTO THE END OF THE STUD.
4. Install the new sway bar link. Install the sway bar link nuts and torque to 88 N.m (65 ft. lbs.).
5. Perform steps 3 and 4 for the other sway bar link.
6. Install both front wheels, use a criss-cross pattern to tighten the lug nuts to 70 N.m (50 ft. lbs.)
and then use a criss-cross pattern again to tighten to
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Stabilizer Link: > 02-004-01 > Jul
> 01 > Front Suspension - Knock/Squawk Sound > Page 6775
a final torque of 135 N.m (100 ft. lbs.).
7. Lower vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Technical Service Bulletins > Page 6776
Stabilizer Link: Specifications
FRONT:
Attaching Nuts .....................................................................................................................................
................................................. 88 Nm (65 ft. lbs.)
REAR:
Attaching Nuts .....................................................................................................................................
................................................. 61 Nm (45 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Description and Operation > Front
Stabilizer Link: Description and Operation Front
The stabilizer bar attaching links are used to attach each end of the stabilizer bar to the front strut
assemblies. This reduces the fore-and-aft rate of the stabilizer bar from the rest of the vehicle's
front suspension.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Stabilizer Bar, Sway Control > Stabilizer Link >
Component Information > Description and Operation > Front > Page 6779
Stabilizer Link: Description and Operation Rear
The 2 rubber isolated link arms are connected to the rear frame rails by brackets. These brackets
are bolted to the bottom of the frame rails.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut
Tower Corrosion
Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut
Tower Corrosion > Page 6788
TIME ALLOWANCE
FAILURE CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 >
Suspension/Body - Strut Tower Corrosion
Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Strut / Shock Tower > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 >
Suspension/Body - Strut Tower Corrosion > Page 6794
TIME ALLOWANCE
FAILURE CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and
Repair > Front Crossmember
Subframe: Service and Repair Front Crossmember
REMOVAL AND INSTALLATION FRONT CROSSMEMBER
The front suspension crossmember must be installed in the design location to achieve proper front
end suspension alignment. If the crossmember is removed without applying reference marks on the
frame rails, align the crossmember according to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement
nut can be obtained through a Mopar Parts supplier.
REMOVAL
1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument
panel. 3. Remove knee blocker reinforcement. 4. Position steering so front wheels are straight
ahead.
CAUTION: DO NOT ROTATE STEERING WHEEL AFTER DISENGAGING LOWER COUPLING
FROM STEERING GEAR, DAMAGE TO AIRBAG CLOCK SPRING CAN RESULT.
Steering Coupling Boot
5. Remove clinch bolt holding steering column coupling to steering gear shaft. 6. Remove steering
column coupling from telescoping steering gear shaft. 7. Hoist and support vehicle on safety
stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using
hose pinch-off pliers C-4390, pinch power steering oil return hose off between the cross-member
coupling and the pump.
10. Loosen hose clamp at the crossmember coupling. 11. Disconnect return hose from metal tube.
12. While holding pressure relief valve nut on back of power steering pump. Remove flare nut
holding high pressure hose to back of pump. 13. Separate high pressure hose from pump. 14.
Allow power steering fluid to drain into pan. 15. Remove bolts holding anti-lock brake sensor leads
to crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar
links from ends of stabilizer bar. Refer to Steering and Suspension. 18. Disconnect lower ball joints
from lower control arms. Refer to Steering and Suspension.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and
Repair > Front Crossmember > Page 6799
Rear Engine Mount
19. Remove bolt holding rear engine mount to crossmember. 20. Using paint or grease pencil,
mark outline of crossmember on frame rails to aid installation.
Crossmember
21. Support crossmember on suitable lifting device.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and
Repair > Front Crossmember > Page 6800
Crossmember Mount
22. Remove bolts holding crossmember to front frame rails.
Crossmember
23. Remove crossmember from vehicle.
INSTALLATION
NOTE: If crossmember requires replacement. Refer to Steering and Suspension, to transfer
steering and suspension components.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and
Repair > Front Crossmember > Page 6801
Crossmember
1. Support crossmember on suitable lifting device. 2. Position crossmember to vehicle. 3. Loosely
install bolts to hold crossmember to front frame rails. 4. Align crossmember to previously made
marks on frame rails. 5. Tighten bolts holding crossmember to frame rails. 6. Install bolt holding
rear engine mount to cross-member. 7. Connect lower ball joints to lower control arms. Refer to
Steering and Suspension. 8. Connect stabilizer bar links to ends of stabilizer bar. Refer to Steering
and Suspension 9. Install bolts to hold anti-lock brake sensor leads to crossmember.
10. Install high pressure hose to pump. 11. Connect return hose to metal tube. 12. Tighten hose
clamp at the crossmember coupling. 13. Remove pinch-off pliers. 14. Position steering so front
wheels are straight ahead. 15. Install steering column coupling to telescoping steering gear shaft.
16. Install clinch bolt to hold steering column coupling to steering gear shaft. 17. Install knee
blocker reinforcement. 18. Install steering column lower cover from instrument panel. 19. Connect
battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Subframe > Component Information > Service and
Repair > Front Crossmember > Page 6802
Subframe: Service and Repair Front Crossmember Mount Bushings
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL
1. Using paint or grease pencil, mark outline of crossmember on frame rails. 2. Loosen bolts
holding crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow
crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing
from vehicle.
INSTALLATION
1. Apply rubber lube or soap to replacement bushing. 2. Insert lower half of bushing into square
hole in crossmember. 3. Place upper half of bushing on top of cross-member aligned to receive
square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to
ensure they are properly mated. 5. Lift crossmember upward to close gap between the bushing and
frame. 6. Verify that lower bushing is fully seated into crossmember and upper bushing. 7. Install
bolt to hold bushing and crossmember to frame rail hand tight. 8. Align crossmember to reference
marks on frame rails. 9. Tighten crossmember to frame rails attaching bolts to 163 Nm 120 ft. lbs.
torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications
Suspension Spring ( Coil / Leaf ): Specifications
Spring Plate To Axle Attaching Bolts
.................................................................................................................................................... 108
Nm (80 ft. lbs.) Rear Mount To Body Bolts ..........................................................................................
............................................................................ 61 Nm (45 ft. lbs.) Front Mount To Body Bolts .......
..............................................................................................................................................................
61 Nm (45 ft. lbs.) To Front Hanger Mounting Nut
............................................................................................................................................................
156 Nm (115 ft. lbs.) Shackle Plate Nuts .............................................................................................
....................................................................................... 61 Nm (45 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Specifications > Page 6806
Suspension Spring ( Coil / Leaf ): Description and Operation
Coil springs are rated separately for each corner or side of the vehicle depending on optional
equipment and type of vehicle service. During service procedures when both springs are removed,
mark springs to ensure installation in original position. Each coil spring comes with a plastic sleeve
on the second coil of the spring. This plastic sleeve is a noise insulator for the coil spring.
NOTE: If coil springs require replacement, be sure that the springs needing replacement are
replaced with springs meeting the correct load rating for the vehicle and its specific options.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing
Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Bushing
1. Install leaf spring in a proper holding fixture. 2. Install leaf spring press Special Tool C-4212-F, or
equivalent. 3. Install adapter Special Tool C-4212-3, or equivalent. 4. Tighten leaf spring press until
bushing is extracted from leaf spring. 5. Remove leaf spring press from leaf spring. 6. Insert
replacement bushing into the leaf spring eye. Verify that the bushing flange is on the outboard side
of the leaf spring. 7. Install leaf spring press Special Tool C-4212-F, or equivalent. 8. Install adapter
Special Tool C-4212-4, or equivalent. 9. Tighten leaf spring press until bushing flange bottoms
solidly against leaf spring eye.
10. Remove leaf spring press and adapter. 11. Bend the bushing tabs so that they are contacting
the leaf spring.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing > Page 6809
Suspension Spring ( Coil / Leaf ): Service and Repair Leaf Spring Replacement
Removal
1. Raise vehicle on frame contact hoist to a comfortable working position. 2. Support axle with a
jack stand. Pad should just contact axle.
3. Begin removal of the shock absorber lower mounting bolt.
NOTE: If shock absorber bolt deflects upward during removal, raise axle by adjusting support jack.
If shock absorber bolt deflects downward during removal, lower axle by adjusting support jack (or
by pulling on axle).
4. Using 2 jack stands positioned under the outer ends of the axle, raise the axle enough to remove
the weight of the axle from the rear springs.
5. Loosen and remove the axle plate bolts from the rear axle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing > Page 6810
6. Remove the axle plate from the rear axle and the leaf spring. 7. Using the jack stands slowly
lower the rear axle, permitting the rear springs to hang free.
8. Loosen and remove the 4 bolts from the front mount of the leaf spring.
9. Loosen and remove the nuts from the spring hanger for the rear leaf spring. Then remove the
hanger plate from the hanger and remove the spring
from the spring hanger.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing > Page 6811
10. Remove the leaf spring from the vehicle.
11. Loosen and remove the pivot bolt from the front mount of the rear leaf spring.
Installation
1. Assemble front spring mount to front of spring eye and install pivot bolt and nut. Do not tighten.
CAUTION: Pivot bolt must face inboard to prevent structural damage during installation of spring.
2. Raise front of spring and install four hanger bolts, tighten to 61 Nm (45 ft. lbs.) torque. 3. Install
rear of spring onto rear spring shackle. Install shackle plate. Do not tighten. 4. Verify lower leaf
spring isolator is in position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing > Page 6812
5. Raise axle assembly into correct position with axle centered under spring locator post. 6. Verify
that the leaf spring isolator is correctly positioned in the axle plate. 7. Install axle plate on the
spring. 8. Install axle plate bolts. Tighten bolts to 108 Nm (80 ft. lbs.) torque. 9. Install shock
absorber bolts. Do not tighten.
10. Lower vehicle to floor so that the full weight of the vehicle is supported by the tires. 11. Tighten
component fasteners as follows:
- Front pivot bolt: 156 Nm (116 ft. lbs.)
- Shackle nuts: 61 Nm (45 ft. lbs.)
- Shock absorber bolts: 101 Nm (75 ft. lbs.)
12. If the vehicle is not equipped with antilock brakes, raise vehicle and connect the actuator for the
height sensing proportioning valve on the rear leaf
spring. Adjust the height sensing proportioning valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing > Page 6813
Suspension Spring ( Coil / Leaf ): Service and Repair Mount Replacement
Front
REMOVE
1. Loosen the pivot bolt attaching the front of the leaf spring to the spring mount.
2. Install a jackstand under the side of the axle having the leaf spring mount removed. Using the
jackstand support the weight of the axle and leaf
spring.
3. Remove the lower mounting bolt from the shock absorber. 4. Remove the bolts attaching the leaf
spring front mount to the body of the vehicle. 5. Lower the leaf spring and remove the front mount
from the spring.
INSTALLATION
1. For installation, reverse removal procedure. Do not tighten front through bolt fully until vehicle is
lowered and the full vehicle weight is applied to
the rear wheels. Tighten leaf spring front mount bolts to 61 Nm (45 ft. lbs.). Tighten leaf spring front
through bolt to 156 Nm (115 ft. lbs.).
Rear
REMOVE
1. Remove the attaching nuts and bolts from the leaf spring rear shackle. 2. Install a jackstand
under the side of the axle having the leaf spring mount removed. Using the jackstand, support the
weight of the axle and leaf
spring.
3. Remove the lower mounting bolt from the shock absorber.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Spring ( Coil / Leaf ) > Component
Information > Service and Repair > Leaf Spring Bushing > Page 6814
4. Remove the bolts attaching the leaf spring rear mount to the body of the vehicle. 5. Lower the
jackstand and the rear of the leaf spring. Remove the shackle from the leaf spring bushing.
INSTALL
1. For installation, reverse removal procedure. Do not tighten rear spring shackle nuts fully until
vehicle is lowered and the full vehicle weight is
applied to the rear wheels. Tighten rear spring mount bolts to 61 Nm (45 ft. lbs.). Tighten shackle
nuts to 61 Nm (45 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise
Technical Service Bulletin # 02-10-98 Date: 980925
Front Strut Bearings - Squeaking/Chirping Noise
NO: 02-10-98
GROUP: Suspension
DATE: Sept. 25, 1998
SUBJECT: Squeaking Noise From Strut Bearing(s)
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998.
SYMPTOM/CONDITION:
A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s)
when turning the steering wheel or when the vehicle is driven over any irregularities in the road
surface.
DIAGNOSIS:
With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180°
apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top
of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower.
Parts Information:
AR (2) 04684418 Bearing, Strut Upper Pivot
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
02-05-39-93 One Side 0.9 Hrs.
02-05-39-94 Two Sides 1.6 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves replacing the strut upper pivot bearing(s).
WARNING:
DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.
1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the
Lubrication and Maintenance section of the service manual, for the required lifting procedure to be
used for this vehicle.
2. Remove the front wheel and tire assembly from the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6823
3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket
from the strut damper brackets (Figure 1).
NOTE:
WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT
ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40
IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2.
4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6824
6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the
strut assembly from the vehicle (Figure 4).
7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment
(PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut
clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring
upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the
strut shaft nut is removed (Figure 5 and 6).
WARNING:
DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING
SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT
NUT IS REMOVED.
8. Compress the coil spring until all coil spring tension is removed from the upper mount.
9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm
socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove
the nut from the strut shaft.
10. Remove the upper mount from the strut shaft.
11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight
up.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6825
12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed
on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7).
Be sure the pivot bearing is sitting flat on the spring seat once mounted.
13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat
(Figure 6). Loosely install the retaining nut on the strut shaft.
14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft
retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding
the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.).
15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully.
As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly.
Remove the clamp from the lower end of the coil spring and strut. Push back the spring
compressor upper and lower hooks, then remove the strut assembly from the spring compressor.
16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut
mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies.
Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3).
NOTE:
IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE
CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS
BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING
THE FRONT OF THE VEHICLE.
18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.)
plus an additional 1/4 turn after specified torque is met.
19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching
link to strut bracket attaching nut.
NOTE:
WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW
STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN
THE END OF THE STUD (FIGURE 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-10-98 > Sep >
98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6826
20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a
torque of 88 Nm (65 ft. lbs.) (Figure 8).
21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly
brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.).
22. Install the wheel/tire assembly on the vehicle.
23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued
to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
24. Repeat step 2 through 23 for the other side strut, if necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-09-98 > Aug >
98 > Rear Shock Absorber - Rattles on Bumps
Suspension Strut / Shock Absorber: Customer Interest Rear Shock Absorber - Rattles on Bumps
NO: 02-09-98
GROUP: Suspension
DATE: Aug. 28, 1998
SUBJECT: Load Leveling Shock Bushing Service
MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH LOAD LEVELING SHOCKS (SALES
CODE SER).
SYMPTOM/CONDITION:
Rattle noise from rear of the vehicle when driving over road bumps.
DIAGNOSIS:
Check all rear shock bolts for proper torque, 101 Nm (75 ft. lbs.). Check upper shock bushing for
wear, rubber debris around bushing or holes and voids in rubber. If the bushing has evidence of
wear, perform the Repair Procedure.
PARTS REQUIRED:
2 05013474AA Bushing, Upper Load Leveling
REPAIR PROCEDURE:
This bulletin involves replacing the upper load leveling shock bushings
1. Using the procedure outlined in group 2 of the appropriate service manual, remove the rear
shocks.
2. Secure ball joint press, special tool C-4212F, in a bench vise. Install the receiver, special tool
8526-1, into the cup of C-4212F, and tighten the set screw. Install the driver, special tool 8526-2,
on the tip of the C-4212F screw drive, (Figure 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-09-98 > Aug >
98 > Rear Shock Absorber - Rattles on Bumps > Page 6831
3. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears
the shock absorber body (Figure 2).
4. Tighten the screw drive until the driver contacts the outer circumference of the bushing evenly.
Continue to tighten the screw drive until the bushing is pressed completely out of the shock
absorber eye and into the receiver.
5. Back off the screw drive and remove the bushing from the receiver.
6. Install the driver, special tool 8526-2, on the tip of the ball joint press screw drive as shown in
Figure 3. Position the driver this way to seat the bushing to its correct depth.
7. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears
the shock absorber body (Figure 4).
8. Position the bushing between the shock absorber eye and the driver. Tighten the screw drive
until the driver, bushing, and shock absorber eye are touching and squarely aligned.
9. Press the bushing into the shock absorber eye until the driver bottoms against the face of the
eye. Back off the ball Joint press screw drive and remove the shock absorber from the press.
10. Repeat steps 2 through 9 for the other shock.
11. Using the procedure outline in section 2 of the appropriate service manual, install the rear
shocks.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Strut / Shock Absorber: > 02-09-98 > Aug >
98 > Rear Shock Absorber - Rattles on Bumps > Page 6832
Labor Operation No: 02-15-15-90 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise
Technical Service Bulletin # 02-10-98 Date: 980925
Front Strut Bearings - Squeaking/Chirping Noise
NO: 02-10-98
GROUP: Suspension
DATE: Sept. 25, 1998
SUBJECT: Squeaking Noise From Strut Bearing(s)
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT THROUGH OCT. 1, 1998.
SYMPTOM/CONDITION:
A squeaking/chirping noise is heard (inside or outside the vehicle) from the strut tower area(s)
when turning the steering wheel or when the vehicle is driven over any irregularities in the road
surface.
DIAGNOSIS:
With the vehicle on a level surface, hold a front suspension coil spring, with your hands near 180°
apart, and try to rotate the spring right and left. If a squeaking/chirping noise is heard from the top
of the strut tower, perform the Repair Procedure. Repeat for the opposite side strut tower.
Parts Information:
AR (2) 04684418 Bearing, Strut Upper Pivot
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
02-05-39-93 One Side 0.9 Hrs.
02-05-39-94 Two Sides 1.6 Hrs.
FAILURE CODE: P8 - New Part
Repair Procedure
This bulletin involves replacing the strut upper pivot bearing(s).
WARNING:
DO NOT REMOVE THE NUT FROM THE STRUT ROD WHILE STRUT ASSEMBLY IS
INSTALLED IN VEHICLE, OR BEFORE STRUT ASSEMBLY SPRING IS COMPRESSED.
1. Raise vehicle on jack stands or centered on a frame contact type hoist. See Hoisting in the
Lubrication and Maintenance section of the service manual, for the required lifting procedure to be
used for this vehicle.
2. Remove the front wheel and tire assembly from the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6838
3. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket
from the strut damper brackets (Figure 1).
NOTE:
WHEN REMOVING NUT FROM STUD OF STABILIZER BAR ATTACHING LINK, DO NOT
ALLOW STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40
IP BIT IN THE END OF THE STUD AS SHOWN IN FIGURE 2.
4. Remove the stabilizer bar attaching link from the bracket on the strut assembly (Figure 2).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING REMOVAL. REMOVE NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
5. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts (Figure 3).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6839
6. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower and remove the
strut assembly from the vehicle (Figure 4).
7. Position the strut assembly in the strut coil spring compressor (Pentastar Service Equipment
(PSE) tool W-7200, or the equivalent) closely following the manufacturers instructions. The strut
clevis bracket should be positioned outward. Position the upper hooks on top of the coil spring
upper seat. Place a clamp on the lower end of the coil spring, so the strut is held in place once the
strut shaft nut is removed (Figure 5 and 6).
WARNING:
DO NOT REMOVE THE STRUT SHAFT NUT BEFORE THE COIL SPRING IS COMPRESSED.
THE COIL SPRING IS HELD UNDER PRESSURE AND MUST BE COMPRESSED, REMOVING
SPRING TENSION FROM THE UPPER MOUNT AND PIVOT BEARING, BEFORE THE SHAFT
NUT IS REMOVED.
8. Compress the coil spring until all coil spring tension is removed from the upper mount.
9. Install Strut Nut Socket, Special Tool 6864, on the strut shaft retaining nut. Next, install a 10 mm
socket on the hex on the end of the strut shaft. While holding the strut shaft from turning, remove
the nut from the strut shaft.
10. Remove the upper mount from the strut shaft.
11. Remove the upper pivot bearing from the top of the coil spring upper seat by pulling it straight
up.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6840
12. Install the new pivot bearing on the top of the upper spring seat. The bearing must be installed
on upper seat with the smaller diameter side of the pivot bearing toward the spring seat (Figure 7).
Be sure the pivot bearing is sitting flat on the spring seat once mounted.
13. Install the upper mount over the strut shaft and onto the top of the pivot bearing and upper seat
(Figure 6). Loosely install the retaining nut on the strut shaft.
14. Install Strut Nut Socket (on the end of a torque wrench), Special Tool 6864, on the strut shaft
retaining nut. Next, install a 10 mm socket on the hex on the end of the strut shaft. While holding
the strut shaft from turning, tighten the strut shaft retaining nut to a torque of 94 Nm (70 ft. lbs.).
15. Slowly release the tension from the coil spring by backing off the spring compressor drive fully.
As the tension is relieved, make sure the upper mount, pivot bearing and upper seat align properly.
Remove the clamp from the lower end of the coil spring and strut. Push back the spring
compressor upper and lower hooks, then remove the strut assembly from the spring compressor.
16. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut
mount into the holes in strut tower. Install the 3 upper strut mount attaching nut/washer assemblies.
Then using a crow foot, tighten the 3 attaching nuts to a torque of 28 Nm (250 in. lbs.).
CAUTION:
THE STEERING KNUCKLE TO STRUT ASSEMBLY ATTACHING BOLTS ARE SERRATED AND
MUST NOT BE TURNED DURING INSTALLATION. INSTALL NUTS WHILE HOLDING BOLTS
STATIONARY IN THE STEERING KNUCKLES.
17. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis bracket mounting holes with the steering knuckle
mounting holes. Install the 2 strut assembly to steering knuckle attaching bolts (Figure 3).
NOTE:
IF STRUT ASSEMBLY IS ATTACHED TO STEERING KNUCKLE USING A CAM BOLT, THE
CAM BOLT MUST BE INSTALLED IN THE LOWER SLOTTED HOLE ON THE STRUT CLEVIS
BRACKET. ALSO, ATTACHING BOLTS SHOULD BE INSTALLED WITH THE NUTS FACING
THE FRONT OF THE VEHICLE.
18. Tighten the strut assembly to steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.)
plus an additional 1/4 turn after specified torque is met.
19. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching
link to strut bracket attaching nut.
NOTE:
WHEN TORQUING NUT ON STUD OF STABILIZER BAR ATTACHING LINK, DO NOT ALLOW
STUD TO ROTATE. HOLD STUD FROM ROTATING BY INSERTING A TORX PLUS 40 IP BIT IN
THE END OF THE STUD (FIGURE 8).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-10-98 > Sep > 98 > Front Strut Bearings - Squeaking/Chirping Noise > Page 6841
20. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40 IP bit and crowfoot to a
torque of 88 Nm (65 ft. lbs.) (Figure 8).
21. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly
brackets (Figure 1). Tighten the routing bracket attaching bolts to a torque of 13 Nm (100 ft. lbs.).
22. Install the wheel/tire assembly on the vehicle.
23. Install and tighten the wheel mounting stud nuts in a cris-cross pattern until all nuts are torqued
to half specification. Then repeat the tightening sequence to the full specified torque of 135 Nm
(100 ft. lbs.).
24. Repeat step 2 through 23 for the other side strut, if necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps
Suspension Strut / Shock Absorber: All Technical Service Bulletins Rear Shock Absorber - Rattles
on Bumps
NO: 02-09-98
GROUP: Suspension
DATE: Aug. 28, 1998
SUBJECT: Load Leveling Shock Bushing Service
MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH LOAD LEVELING SHOCKS (SALES
CODE SER).
SYMPTOM/CONDITION:
Rattle noise from rear of the vehicle when driving over road bumps.
DIAGNOSIS:
Check all rear shock bolts for proper torque, 101 Nm (75 ft. lbs.). Check upper shock bushing for
wear, rubber debris around bushing or holes and voids in rubber. If the bushing has evidence of
wear, perform the Repair Procedure.
PARTS REQUIRED:
2 05013474AA Bushing, Upper Load Leveling
REPAIR PROCEDURE:
This bulletin involves replacing the upper load leveling shock bushings
1. Using the procedure outlined in group 2 of the appropriate service manual, remove the rear
shocks.
2. Secure ball joint press, special tool C-4212F, in a bench vise. Install the receiver, special tool
8526-1, into the cup of C-4212F, and tighten the set screw. Install the driver, special tool 8526-2,
on the tip of the C-4212F screw drive, (Figure 1).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps > Page 6846
3. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears
the shock absorber body (Figure 2).
4. Tighten the screw drive until the driver contacts the outer circumference of the bushing evenly.
Continue to tighten the screw drive until the bushing is pressed completely out of the shock
absorber eye and into the receiver.
5. Back off the screw drive and remove the bushing from the receiver.
6. Install the driver, special tool 8526-2, on the tip of the ball joint press screw drive as shown in
Figure 3. Position the driver this way to seat the bushing to its correct depth.
7. Place the shock absorber upper mounting eye in the receiver so the notch in the receiver clears
the shock absorber body (Figure 4).
8. Position the bushing between the shock absorber eye and the driver. Tighten the screw drive
until the driver, bushing, and shock absorber eye are touching and squarely aligned.
9. Press the bushing into the shock absorber eye until the driver bottoms against the face of the
eye. Back off the ball Joint press screw drive and remove the shock absorber from the press.
10. Repeat steps 2 through 9 for the other shock.
11. Using the procedure outline in section 2 of the appropriate service manual, install the rear
shocks.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Strut / Shock Absorber: >
02-09-98 > Aug > 98 > Rear Shock Absorber - Rattles on Bumps > Page 6847
Labor Operation No: 02-15-15-90 0.9 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications > Shock Absorber
Suspension Strut / Shock Absorber: Specifications Shock Absorber
Mounting Bolts (All) .............................................................................................................................
................................................. 101 Nm (75 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Specifications > Shock Absorber > Page 6850
Suspension Strut / Shock Absorber: Specifications Struts
Tower Attaching Nuts ..........................................................................................................................
............................................... 28 Nm (250 inch lbs.) Clevis Bracket To Steering Knuckle
.................................................................................................................................. 88 Nm (65 ft.
lbs.) Plus 1/4 Turn Shaft Nut ...............................................................................................................
.................................................................................. 100 Nm (75 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Description and Operation > Front
Suspension Strut / Shock Absorber: Description and Operation Front
The front suspension of the vehicle is supported by coil springs positioned around the strut
assembly. The springs are contained between an upper seat, located just below the top strut mount
assembly and a lower spring seat on the strut fluid reservoir.
The top of each strut assembly is bolted to the upper fender reinforcement (strut tower) through a
rubber isolated mount.
The bottom of the strut assembly attaches to the steering knuckle with two through bolts. Caster is
a fixed setting on all vehicles and is not adjustable when an alignment is performed. In the event
the camber setting on a vehicle requires adjustment, a service strut is available which will provide a
method by which the camber can be adjusted.
The strut assemblies on this vehicle are inter-connected by the front stabilizer bar through 2 link
assemblies attaching the struts to the stabilizer bar.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Description and Operation > Front > Page 6853
Suspension Strut / Shock Absorber: Description and Operation Shock Absorber
REAR LOAD LEVELING
A new type of load-leveling shock is available.
Description The self leveling shock absorbers are a self-contained vehicle leveling system and
shock absorber combined.
Requirements It does not require an external compressor, hoses, height leveling sensors, etc. It
uses road inputs (bumps, stops, starts, turns, acceleration, deceleration, etc.) to activate pumping,
which is just the extension and compression of the shock absorber.
Design On the outside, it looks like a larger than normal shock absorber. Internally, it consists of a
hydraulic pump and gas-spring cushion for leveling, as well as the normal shock absorbing
mechanism. All the height leveling sensors, pump, etc., are contained inside the shocks.
Mounting The shocks are mounted at an angle, parallel to the springs and forward at the top. This
design provides greater stability in addition to controlling ride motion. These new load-leveling
shock absorbers use longer fasteners than the standard shock absorbers, although the fasteners
are longer, the torque specifications are the same.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Description and Operation > Page 6854
Suspension Strut / Shock Absorber: Testing and Inspection
1. Inspect for damaged or broken coil springs. 2. Inspect for torn or damaged strut assembly dust
boots. 3. Inspect the coil spring isolator on the lower spring seat, for any signs of damage or
deterioration.
4. Lift dust boot and inspect strut assembly for evidence of fluid running from the upper end of fluid
reservoir. (Actual leakage will be a stream of
fluid running down the side and dripping off lower end of unit). A slight amount of seepage between
the strut rod and strut shaft seal is not unusual and does not affect performance of the strut
assembly. Also inspect jounce bumpers for signs of damage or deterioration.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement
Suspension Strut / Shock Absorber: Service and Repair Shock Absorber Replacement
REMOVAL/INSTALLATION
1. Raise vehicle. Vehicle is to be raised and supported on jackstands or on a frame contact type
hoist. 2. Support the rear axle of the vehicle using 2 jackstands positioned at the outer ends of the
axle.
NOTE: If the shock absorber lower mounting bolt deflects upward during removal, raise axle by
adjusting the support jack. If the lower shock absorber bolt deflects downward during removal,
lower the axle by adjusting the support jack.
3. Remove the shock absorber lower mounting bolt. 4. While holding shock absorber, remove the
shock absorber upper mounting bolt. 5. To install the shock absorber use the reverse sequence of
its removal. 6. Lower the vehicle to the ground so the full weight of the vehicle is supported by the
suspension. 7. Tighten the upper and lower shock absorber mounting bolt to their specified
torques.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6857
Suspension Strut / Shock Absorber: Service and Repair Replacement
Removal
WARNING: Do not remove the nut from the strut rod while strut assembly is installed in vehicle, or
before strut assembly spring is compressed.
1. Raise vehicle on jack stands or centered on a frame contact type hoist. 2. Remove the wheel
and tire assembly from location on front of vehicle requiring strut removal. 3. If both strut
assemblies are to be removed, mark the strut assemblies right or left according to which side of the
vehicle they were removed from.
4. Remove the hydraulic brake hose routing bracket and the speed sensor cable routing bracket
from the strut damper brackets.
NOTE: When removing nut from stud of stabilizer bar attaching link, do not allow stud to rotate.
Hold stud from rotating by inserting a Torx Plus 40IP bit in the end of the stud as shown.
5. Remove the stabilizer bar attaching link from the bracket on the strut assembly.
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during removal. Remove nuts while holding bolts stationary in the steering knuckles.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6858
6. Remove the 2 strut assembly clevis bracket to steering knuckle attaching bolts.
7. Remove the 3 nuts attaching the strut assembly upper mount to the strut tower.
Installation
1. Install strut assembly into strut tower, aligning and installing the 3 studs on the upper strut mount
into the holes in shock tower. Install the 3 upper
strut mount attaching nut/washer assemblies. Then using a crow foot. tighten the 3 attaching nuts
to a torque of 28 Nm (250 inch lbs.).
CAUTION: The steering knuckle to strut assembly attaching bolts are serrated and must not be
turned during installation. Install nuts while holding bolts stationary in the steering knuckles.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6859
2. Align strut assembly with steering knuckle. Position arm of steering knuckle into strut assembly
clevis bracket. Align the strut assembly clevis
bracket mounting holes with the steering knuckle mounting holes. Install the 2 strut assembly to
steering knuckle attaching bolts. If strut assembly is attached to steering knuckle using a cam bolt,
the cam bolt must be installed in the lower slotted hole on strut clevis bracket. Also, attaching bolts
should be installed with the nuts facing the front of the vehicle. Tighten the strut assembly to
steering knuckle attaching bolts to a torque of 88 Nm (65 ft. lbs.) plus an additional 1/4 turn after
specified torque is met.
3. Install stabilizer bar attaching link on bracket of strut assembly. Install stabilizer bar attaching link
to strut bracket attaching nut.
NOTE: When torquing nut on stud of stabilizer bar attaching link, do not allow stud to rotate. Hold
stud from rotating by inserting a Torx Plus 401P bit in the end of the stud as shown.
4. Tighten the stabilizer bar link to strut attaching nut using a Torx Plus 40IP bit and crowfoot as
shown to a torque of 88 Nm (65 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6860
5. Install hydraulic brake hose and speed sensor cable routing brackets on the strut assembly
brackets. Tighten the routing bracket attaching bolts to a
torque of 13 Nm (10 ft. lbs.).
6. Install the wheel/tire assembly on the vehicle. 7. Install and tighten the wheel mounting stud nuts
in proper sequence until all nuts are torqued to half specification. Then repeat the tightening
sequence to the full specified torque of 135 Nm (100 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6861
Suspension Strut / Shock Absorber: Service and Repair Overhaul
Disassembly
NOTE: The Mc Pherson Strut must be remove from the vehicle for it to be disassembled and
assembled.
1. Clamp strut assembly in vise, with strut in a vertical position. Do not clamp reservoir of strut
assembly in vise, only clamp strut assembly using
strut clevis bracket.
2. Mark coil spring and strut assembly right or left, according to which side of vehicle strut was
removed from, and which strut coil spring was
removed from.
Compressing Strut Assembly Coil Spring
WARNING: Do not remove strut rod nut, before strut assembly coil spring is compressed, removing spring
tension from upper spring seat and bearing assembly.
- When compressing coil spring for removal from strut assembly, the upper spring seat and second
coil of the coil spring must be captured by the jaws of the coil spring compressor.
3. Compress strut assembly coil spring, using Pentastar Service Equipment Spring Compressor,
7522A or equivalent. Be sure the top and bottom
attachment shoe selected, properly fit the coil spring.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6862
4. Install Socket, Strut Nut, Special Tool 6864 on the Strut shaft retaining nut. Then install a 10 mm
socket on the hex of the strut damper shaft.
While holding strut shaft from turning, remove the strut shaft retaining nut.
Strut Assembly Upper Mount
5. Remove the upper strut mount from the strut assembly.
6. Release the coil spring from the spring compressor. Then remove the spring compressor from
the coil spring. 7. Remove the upper spring seat and the pivot bearing as an assembly from the coil
spring. Then remove the coil spring from the strut assembly.
Mark left and right springs for installation back on correct side of vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6863
8. Remove the dust shield and the jounce bumper as an assembly from strut shaft. The dust shield
can not be removed from the jounce bumper until
after it is removed from strut shaft.
9. Remove the jounce bumper from the dust shield. Jounce bumper is removed from dust shield by
collapsing dust shield until jounce bumper can be
grabbed onto and then pulled out of the dust boot.
10. Remove the spring isolator from the strut assembly lower spring seat. 11. Inspect strut damper
for any condition of shaft binding over full stroke of the shaft. 12. Inspect the strut mount and the
upper spring seat assembly for the following:
- Mount for cracks and distortion and retaining studs for any sign of damage.
- Severe deterioration of rubber isolator,
- Binding strut assembly pivot bearing. If pivot bearing is replaced it is to be installed with the larger
diameter end of bearing facing up.
- Inspect dust shield for rips and/or deterioration.
- Inspect jounce bumper for cracks and signs of deterioration.
13. Replace any components of the strut assembly found to be worn or defective during the
inspection, before re-assembling the strut.
Assembly
1. Clamp strut assembly in vise, with strut in a vertical position. Do not clamp reservoir of strut
assembly in vise, only clamp the strut assembly in
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6864
vise using clevis bracket.
2. Install the spring isolator on the strut lower spring seat. When installing the spring isolator, be
sure the 2 retaining tabs on the spring isolator are
installed in the 2 holes in the spring seat. When properly installed, the oversize holes in the spring
seat should line up with the holes in the spring isolator.
WARNING: If a replacement coil spring is to be installed on the strut assembly, the first full top and
bottom coil of the spring must be captured by the jaws of the coil spring compressor.
3. Install the jounce bumper on the shaft of the strut assembly. Jounce bumper is to be installed
with the small end of the jounce bumper pointing
down.
4. Install the dust shield on the strut assembly. After dust shield is installed on strut, collapse dust
shield down on top of jounce bumper until jounce
bumper snaps into dust shield. Then return the dust shield to its fully extended length.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6865
5. Install coil spring onto strut. Spring is to be installed with the end of the bottom coil aligned with
the clevis bracket on the strut assembly. 6. Install the upper spring seat on the coil spring. Spring
seat must be installed with the notch in the spring seat aligned with the clevis bracket on the
strut assembly.
7. Compress strut assembly coil spring, using Pentastar Service Equipment Spring Compressor,
7522A or equivalent. Be sure the top and bottom
attachment shoe selected, properly fit the coil spring.
8. Install the strut assembly pivot bearing on the top of the upper spring seat. Bearing must be
installed on spring seat with the smaller diameter side
of the pivot bearing toward the spring seat. Also, be sure the pivot bearing is sitting flat on the
spring seat.
9. Install the strut mount on the upper spring seat of the strut assembly. Then loosely install the nut
on strut shaft.
WARNING: The following 2 steps must be completely done before spring compressor is released
from the coil spring.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Shock Absorber Replacement > Page 6866
10. Install Socket, Strut Nut, Special Tool 6864 on the strut shaft retaining nut. Then install a 10
mm socket on the hex of the strut damper shaft.
While holding strut shaft from turning, torque strut shaft retaining nut to 94 Nm (70 ft. lbs.).
11. Loosen Spring Compressor, Special Tool GP-2020-S2.6, or equivalent until top coil of spring is
fully seated against upper spring seat. Then
relieve all tension from spring compressor and remove spring compressor from strut assembly
spring.
12. Install the strut assembly back in the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Strut / Shock Absorber > Component
Information > Service and Repair > Page 6867
Special Tool 6864
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-09-97A > Oct > 97 >
Rear Suspension - Thumping Noise
Suspension Travel Bumper: Customer Interest Rear Suspension - Thumping Noise
NO: 02-09-97 Rev. A
GROUP: Suspension
DATE: Oct. 24, 1997
SUBJECT:
Thumping Noise At Rear Of Vehicle During Cold Operations
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-09-97 WHICH SHOULD
BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
AND INCLUDES A CLARIFICATION OF AFFECTED MODELS AND PARTS REQUIRED.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SUSPENSION SALES CODE SDB
OR ALL WHEEL DRIVE (AWD).**
SYMPTOM/CONDITION:
Thumping noise from the rear jounce bumpers when driving over small bumps after the vehicle has
been in very cold temperatures (below 100 F.) for three hours or longer.
DIAGNOSIS:
After the vehicle has been exposed to temperatures of 100 F. (-12° C.) or below, load the vehicle
so the rear jounce bumpers are 1/2 in. (13 mm) away from the rear axle. Drive the vehicle over
small bumps and listen for a thumping noise. The condition should improve if the temperature
increases or the after the vehicle has been driven a few miles. If the thumping noise is heard,
perform the Repair Procedure.
PARTS REQUIRED:
AR (2) 04684756AB Bumper, Jounce Front Wheel Drive (FWD)
AR (2) 04684758AB Bumper, Jounce All Wheel Drive (AWD)
**NOTE:
DO NOT INSTALL JOUNCE BUMPERS MADE OF URETHANE (NOT BLACK) ON VEHICLES
ORIGINALLY EQUIPPED WITH RUBBER (BLACK) JOUNCE BUMPERS.**
REPAIR PROCEDURE:
This bulletin involves replacing the rear axle jounce bumpers.
1. Using slip-joint pliers, grasp the base of the jounce bumper and turn counter-clockwise.
2. Separate the jounce bumper from the vehicle and discard.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Technical Service Bulletins > Customer Interest for Suspension Travel Bumper: > 02-09-97A > Oct > 97 >
Rear Suspension - Thumping Noise > Page 6876
3. Install the appropriate revised jounce bumper specified in Parts Required.
4. Repeat steps 1 through 3 for the other side jounce bumper.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 02-30-04-90 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A >
Oct > 97 > Rear Suspension - Thumping Noise
Suspension Travel Bumper: All Technical Service Bulletins Rear Suspension - Thumping Noise
NO: 02-09-97 Rev. A
GROUP: Suspension
DATE: Oct. 24, 1997
SUBJECT:
Thumping Noise At Rear Of Vehicle During Cold Operations
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 02-09-97 WHICH SHOULD
BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**
AND INCLUDES A CLARIFICATION OF AFFECTED MODELS AND PARTS REQUIRED.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager 1996 - 1998 (GS) Chrysler Voyager
(International Market)
**NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH SUSPENSION SALES CODE SDB
OR ALL WHEEL DRIVE (AWD).**
SYMPTOM/CONDITION:
Thumping noise from the rear jounce bumpers when driving over small bumps after the vehicle has
been in very cold temperatures (below 100 F.) for three hours or longer.
DIAGNOSIS:
After the vehicle has been exposed to temperatures of 100 F. (-12° C.) or below, load the vehicle
so the rear jounce bumpers are 1/2 in. (13 mm) away from the rear axle. Drive the vehicle over
small bumps and listen for a thumping noise. The condition should improve if the temperature
increases or the after the vehicle has been driven a few miles. If the thumping noise is heard,
perform the Repair Procedure.
PARTS REQUIRED:
AR (2) 04684756AB Bumper, Jounce Front Wheel Drive (FWD)
AR (2) 04684758AB Bumper, Jounce All Wheel Drive (AWD)
**NOTE:
DO NOT INSTALL JOUNCE BUMPERS MADE OF URETHANE (NOT BLACK) ON VEHICLES
ORIGINALLY EQUIPPED WITH RUBBER (BLACK) JOUNCE BUMPERS.**
REPAIR PROCEDURE:
This bulletin involves replacing the rear axle jounce bumpers.
1. Using slip-joint pliers, grasp the base of the jounce bumper and turn counter-clockwise.
2. Separate the jounce bumper from the vehicle and discard.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Suspension Travel Bumper: > 02-09-97A >
Oct > 97 > Rear Suspension - Thumping Noise > Page 6882
3. Install the appropriate revised jounce bumper specified in Parts Required.
4. Repeat steps 1 through 3 for the other side jounce bumper.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 02-30-04-90 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Technical Service Bulletins > Page 6883
Suspension Travel Bumper: Specifications
To Frame Rail ......................................................................................................................................
............................................... 33 Nm (290 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Standard
Suspension Travel Bumper: Service and Repair Standard
NOTES:
- There are two types of jounce bumpers available depending on which suspension option the
vehicle is equipped with.
- The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a
weld nut located on the frame rail.
REMOVAL
1. Using the proper tool, remove the bolt attaching the jounce bumper to frame rail. 2. Remove the
jounce bumper from the frame rail.
INSTALLATION
1. For installation, reverse the removal procedure. Tighten the jounce bumper mounting bolt to a
torque of 33 Nm (290 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Suspension Travel Bumper > Component
Information > Service and Repair > Standard > Page 6886
Suspension Travel Bumper: Service and Repair Heavy Duty
NOTES:
- There are two types of jounce bumpers available depending on which suspension option the
vehicle is equipped with.
- The jounce bumper is serviced as an assembly. The jounce bumper mounts to the frame rail at a
weld nut located on the frame rail.
REMOVAL
1. Using slip-joint pliers grasp the base of the jounce bumper. Turn the base counterclockwise. 2.
Remove the jounce bumper from the frame rail.
INSTALLATION
1. For installation, reverse the removal procedure. Tighten the jounce bumper to a torque of 33 Nm
(290 inch lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information >
Specifications
Trailing Arm: Specifications
To Axle And Mounting Bracket Pivot Bolt
.............................................................................................................................................. 95 Nm
(70 ft. lbs.) Bracket To Body Attaching Bolt
..............................................................................................................................................................
61 Nm (45 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information >
Specifications > Page 6890
Trailing Arm: Description and Operation
On applications of this vehicle that are equipped with single leaf rear springs a track bar is used on
the rear axle.
The track bar connects the rear axle to the frame/body of the vehicle. The track bar is isolated form
the body of the vehicle by an isolator bushing located in each end of the track bar.
The track bar prevents excessive side to side movement of the rear axle. The track bar is used to
keep the location of the axle in the correct position for optimum handling and control of the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Trailing Arm > Component Information >
Specifications > Page 6891
Trailing Arm: Service and Repair
REMOVE
1. Remove the track bar from the track bar mount.
2. Remove the three bolts attaching the track bar mount to the body.
INSTALLATION
1. For installation, reverse removal procedure. Tighten bolts to 61 Nm (45 ft. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 6895
Wheel Bearing: Description and Operation
The rear hub and bearing assembly used on this vehicle is serviceable only as a complete
assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort
to repair it.
The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are
removable from the back of the rear hub/bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 6896
Wheel Bearing: Testing and Inspection
The rear hub and bearing assembly is designed for the life of the vehicle and should require no
maintenance. The following procedure may be used for evaluation of bearing condition.
With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral
play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings
exhibit these conditions during inspection, the hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive grease loss may also require bearing
replacement. Moderate grease loss from bearing is considered normal and should not require
replacement of the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 6897
Wheel Bearing: Service and Repair
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and
tire. 3. Remove brake drum from hub/bearing.
4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed
sensor during removal and installation of the
hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless
the speed sensor is removed first.
CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on
the tone wheel will result in false ABS cycling and corrosion of the tone wheel.
5. Remove the 4 bolts attaching the hub/ bearing to the rear axle.
CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the
hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle
by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on
the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in
noise or failure of the bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Bearing > Component Information >
Specifications > Page 6898
6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or
equivalent and following procedure to press the
hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and
against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of
Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the
bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should
be against and supported by the axle plate when pressing the wheel bearing out of the axle. If
Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the
flashing from the hole until tool fits properly.
d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or
equivalent. Tighten bolt against Special Tool 8214-1
or equivalent.
e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special
Tool 8214-1 or equivalents.
Removing Rear Hub/Bearing From Axle
7. Remove the hub/bearing from the rear axle and brake support plate.
INSTALL
1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2.
Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3.
Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle.
4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the
proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Suspension > Wheel Hub > Axle Nut > Component Information >
Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Tires > Spare Tire > Component Information >
Description and Operation
Spare Tire: Description and Operation
The temporary spare tire is designed for emergency use only. The original tire should be repaired
and reinstalled at the first opportunity, or replaced with a new. Do not exceed speeds of 50 MPH
when the temporary spare tire is in use on the vehicle. Refer to the Owner's Manual for complete
details.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6916
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6917
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6918
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6919
WHEEL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6920
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6921
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6922
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Customer Interest for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6923
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble.
Technical Service Bulletin # 22-03-99 Date: 990423
Tires/Wheels - Smooth Road Vibration/Shake/Wobble.
NUMBER: 22-03-99
GROUP: Wheels & Tires
DATE: April 23, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 22-02-94 REV. A, DATED
OCT. 21, 1994, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1994
SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-95054). THIS IS A COMPLETE
REVISION AND NO **ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
SUBJECT: Smooth Road Vibration/Shake/Wobble
OVERVIEW:
This bulletin involves diagnosis and correction information for vehicles with a smooth road
high-speed vibration or shake condition.
Low-speed Lateral wobble of the body and/or steering wheel at speeds less than 35 mph (56 kph)
is addressed by TSB 22-02-99.
Mid-speed Steering wheel/seat cyclic vibration (33-35 mph (53-56 kph)) on vehicles equipped with
3.0L engine and 31TH transaxle is addressed by TSB 19-04-97.
High-speed Vibration is characterized by vibration in the seat, floor, instrument panel, and/or
steering wheel at speeds greater than 60 mph (97 kph).
MODELS: 1992 - 1995 (AS) Town & Country/Caravan/Voyager 1993 - 1995 (ES) Chrysler Voyager
(European Market) 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler
Voyager (International Market)
EQUIPMENT REQUIRED:
Tire & Wheel Runout Gauge (PSE # HE490 or equivalent recommended) Off Car Tire & Wheel
Balancer (PSE # H-GSP9702DDR or equivalent recommended) On Car Tire & Wheel Balancer
(Hoffman Finishbalancer or equivalent recommended) Dial Indicator 2-3 In. Micrometer Dial Caliper
POLICY: Information Only
Diagnosis and Correction
Visual Inspection of the vehicle is recommended prior to the initial test drive. Put the vehicle on a
hoist and inspect the following items:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6929
VISUAL INSPECTION
Test Drive the vehicle, in the as received condition, at the complaint speed on a smooth road
surface with all accessories turned off. Correct any obvious safety related items identified during
the Visual Inspection prior to the Test Drive. It is essential to the diagnosis that the repair facility
has identified a smooth road and uses it for the entire diagnosis. A smooth surface will reduce the
vehicle response to road inputs and allow the diagnosis to concentrate on the rotating components.
If the vibration condition has been corrected due to replacement of component(s) return the vehicle
to the customer. If the vibration problem is still present make the following checks:
^ If the vibration changes as you coast in neutral, the problem may be with the driveline, refer to the
Service Manual.
^ If the vibration does not change while coasting then the problem may be caused by tires, wheels
or suspension.
^ If the vibration increases with increasing vehicle speed, the problem may be with imbalance of
rotating components (tires, wheels, half shafts, drums or rotors).
^ If the vibration decreases with increasing vehicle speed, the problem may be with tire/wheel
assembly run out.
^ If the vibration is a low-speed lateral wobble of the body and/or steering wheel oscillations at
speeds less than 45 mph (72 kph), the problem may be caused by lateral run out of the tire/wheel
assembly.
^ If the vibration is a mid-speed vibration and is characterized by vibration in the seat, floor, and/or
steering wheel at speeds between 35-45 mph (56-72 kph); the problem may be caused by high 2nd
order tire/wheel assembly excitation. If torque sensitive, the problem may be driveline related, refer
to the Service Manual.
^ If the vibration is a high-speed vibration and is characterized by vibration in the seat, floor,
instrument panel, and/or steering wheel at speeds greater than 60 mph (97 kph); the problem may
be caused by high 1st order tire/wheel assembly excitation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6930
ON CAR TIRE/WHEEL ASSEMBLY RUNOUT
After your initial Test Drive, correct any deficiencies that the initial Visual Inspection identified. Test
Drive the vehicle, if the vibration condition has been corrected due to replacement of component(s)
return the vehicle to the customer. If the vibration is still present and it was determined that the
vibration is not driveline related proceed to the On Car Tire/Wheel Assembly Runout procedure.
Tire/Wheel Match Mounting is a technique used to reduce radial runout of the tire and wheel
assemblies. Excessive runout is a source of ride complaints and Match Mounting is a method of
reducing runout.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6931
TIRE/WHEEL MATCH MOUNTING
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6932
WHEEL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6933
WHEEL BORE PILOT DIAMETERS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6934
HUB WHEEL PILOT DIAMETER
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6935
HUB WHEEL PILOT RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Wheels: > 22-03-99 > Apr > 99 > Tires/Wheels - Smooth Road
Vibration/Shake/Wobble. > Page 6936
WHEEL MOUNTING SURFACE LATERAL RUNOUT
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Technical
Service Bulletins > Page 6937
Wheels: Description and Operation
Original equipment wheels are designed for proper operation at all loads up to the specified
maximum vehicle capacity.
All models use steel or aluminum drop center wheels. Every wheel has raised sections between
the rim flanges and rim drop well called safety humps.
Initial inflation of the tires forces the bead over these raised sections. In case of air loss the raised
sections hold the tire in position on the wheel until the vehicle can be brought to a safe stop.
Cast aluminum wheels require special balance weights to fit on the thicker flange of the rim and
special wheel clamps for the alignment equipment.
Do not use replacement parts of lesser quality or of a substitute design from the original equipment
part.
All aluminum wheels have wheel stud nuts with an enlarged nose. This enlarged nose is necessary
to ensure proper retention of the wheels.
Before installing a wheel, remove any buildup of corrosion on the wheel mounting surface.
CAUTION: Installing wheels without good metal-to-metal contact could cause loosening of wheel
lug nuts. This could adversely affect the safety and handling of your vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing
and Inspection > General Information
Wheels: Testing and Inspection General Information
Wheels must be replaced if they:
- Have excessive run out
- Are bent or dented
- Leak air
- Have damaged wheel lug holes
Wheel repairs employing hammering, heating, welding or repairing leaks are not allowed.
Original equipment replacement wheels are available through the dealer. When obtaining
replacement wheels from any other source, they must be equivalent in load carrying capacity. The
wheel features (diameter, width, offset, brake clearance, and mounting configuration) must match
the original equipment wheels.
CAUTION: Failure to use original equipment replacement wheels may adversely affect the safety
and handling of your vehicle.
CAUTION: Replacement with used wheels is not recommended. The service history of the rim may
have included severe treatment or very high mileage. The rim could fail without warning.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing
and Inspection > General Information > Page 6940
Wheels: Testing and Inspection Tire and Wheel Runout
NOTE: Runout should always be measured off the vehicle and on a suitable balance machine.
GENERAL INFORMATION
Radial run out is the difference between the high and low points on the outer edge of the tire or
wheel. Lateral run out is the total side-to-side wobble of the tire or wheel. Radial run out of more
than 0.762 mm (0.030 inch) measured at the center line of the tread may cause the vehicle to
shake. Lateral run out of more than 0.762 mm (0.030 inch) measured at the side of the tire as close
to the tread as possible may cause the vehicle to shake. Sometimes radial run out can be reduced
by relocating the wheel and tire on the wheel studs (See Method 1). If this does not reduce run out
to an acceptable level, the tire can be rotated on the wheel. (See Method 2).
Method 1 (Relocate Wheel On Hub) Check accuracy of the wheel mounting surface; adjust wheel
bearings. Drive vehicle a short distance to eliminate tire flat spotting from a parked position.
Fig. 2
Verify all wheel nuts are properly torqued.
Fig. 3
Use run out gauge D-128-TR, or equivalent to determine run out. Relocate the wheel on the
mounting studs, two studs over from the original position. Retighten wheel nuts until all are properly
torqued. This will prevent brake distortion.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing
and Inspection > General Information > Page 6941
Check radial run out. If still excessive, mark tire sidewall, wheel, and stud at point of maximum run
out and proceed to Method 2.
Method 2 (Relocate Tire On Wheel) Rotating tire on wheel is particularly effective when there is run
out in both tire and wheel. Remove tire from wheel and remount wheel on hub in former position.
Fig. 5
Check wheel radial run out. It should be no more than 0.5 mm (0.020 inch) for steel wheels and
0.38 mm (0.015 inch) for cast aluminum wheels.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Testing
and Inspection > General Information > Page 6942
Fig. 6
Check wheel lateral run out. It should be no more than 0.8 mm (0.032 inch). If the point of greatest
wheel radial run out is near the original chalk mark, remount the tire on the rim 180 degrees from
its original position. Recheck the run out. If this does not reduce the run out to an acceptable level,
replace the wheel and/or the tire.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service
and Repair > Balance
Wheels: Service and Repair Balance
Balancing need is indicated by vibration of seats, floor pan, or steering wheel. The vibration will be
noticed mostly when driving over 90 km/h (55 mph) on a smooth road.
It is recommended that a two plane dynamic balancer be used when a wheel and tire assembly
require balancing. Static balancing should be used only when a two plane balancer is not available.
Off-vehicle tire and wheel balancing is recommended to be used on this vehicle.
NOTE: If on vehicle equipment is being used to balance the tire/wheel assemblies, remove the
opposite tire/wheel from the vehicle.
Fig. 7
For static balancing, find the location of heavy spot on tire/wheel causing the imbalance. Counter
balance wheel directly opposite the heavy spot. Determine weight required to counterbalance the
area of imbalance. Place half of this weight on the inner rim flange and the other half on the outer
rim flange.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service
and Repair > Balance > Page 6945
Fig. 8
For dynamic balancing, the balancing equipment is designed to indicate the location and amount of
weight to be applied to both the inner and outer rim flanges.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheels > Component Information > Service
and Repair > Balance > Page 6946
Wheels: Service and Repair Installation
Fig. 2
To install the wheel, first position it properly on the mounting surface of the hub using the hub pilot
as a guide. All wheel nuts should be lightly tightened before progressively tightening them in the
proper sequence. Then fully tighten the wheel nuts in the proper sequence to a torque of 135 Nm
(100 ft. lbs.). Never use oil or grease on studs or nuts.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications
Wheel Bearing: Specifications Lubricant Type
Lubricant Type
Wheel Bearing Grease NLGI GC rated automotive grease
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 6950
Wheel Bearing: Description and Operation
The rear hub and bearing assembly used on this vehicle is serviceable only as a complete
assembly. No attempt should be made to disassemble a rear hub and bearing assembly in an effort
to repair it.
The rear hub and bearing assembly is attached to the rear axle using 4 mounting bolts that are
removable from the back of the rear hub/bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 6951
Wheel Bearing: Testing and Inspection
The rear hub and bearing assembly is designed for the life of the vehicle and should require no
maintenance. The following procedure may be used for evaluation of bearing condition.
With wheel and brake drum removed, rotate flanged outer ring of hub. Excessive roughness, lateral
play or resistance to rotation may indicate dirt intrusion or bearing failure. If the rear wheel bearings
exhibit these conditions during inspection, the hub and bearing assembly should be replaced.
Damaged bearing seals and resulting excessive grease loss may also require bearing
replacement. Moderate grease loss from bearing is considered normal and should not require
replacement of the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 6952
Wheel Bearing: Service and Repair
REMOVE
1. Raise vehicle on jackstands or centered on a frame contact type hoist. 2. Remove wheel and
tire. 3. Remove brake drum from hub/bearing.
4. Remove rear wheel speed sensor from rear hub/bearing. This will prevent damage to the speed
sensor during removal and installation of the
hub/bearing. The rear wheel speed sensor bolts to the hub/bearing. It can not be removed unless
the speed sensor is removed first.
CAUTION: When working in the area of the rear hub/bearing and when removing it from the rear
axle, care must be used so the teeth on the tone wheel are not damaged. Damage to the teeth on
the tone wheel will result in false ABS cycling and corrosion of the tone wheel.
5. Remove the 4 bolts attaching the hub/ bearing to the rear axle.
CAUTION: Corrosion may occur between the hub/ bearing and the axle. If this occurs the
hub/bearing will be difficult to remove from the axle. If the hub/bearing will not come out of the axle
by pulling on it by hand, do not Pound on the hub/bearing to remove it from the axle. Pounding on
the hub/bearing to remove it from the axle will damage the hub/ bearing. This damage will result in
noise or failure of the bearing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Bearing > Component Information >
Specifications > Page 6953
6. If hub/bearing cannot be removed from the axle by hand, use Remover Special Tool 8214 or
equivalent and following procedure to press the
hub/bearing out of the axle. a. Place Special Tool 8214-1 or equivalent over tone wheel and
against cast flange of hub/bearing b. Put a dab of grease in the bolt pilot hole on the back of
Special Tool 8214-1 or equivalent. c. Insert Special Tool 8214-2 or equivalent into the hole in the
bottom of the end casting on the axle. Special Tool 8214-2 or equivalent should
be against and supported by the axle plate when pressing the wheel bearing out of the axle. If
Special Tool 8214-2 or equivalent will not fit into the hole in the end casting, file or grind the
flashing from the hole until tool fits properly.
d. Align bolt in Special Tool 8214-2 or equivalent with pilot hole in Special Tool 8214-1 or
equivalent. Tighten bolt against Special Tool 8214-1
or equivalent.
e. Press hub/bearing out of axle by continuing to tighten bolt in Special Tool 8214-2 against Special
Tool 8214-1 or equivalents.
Removing Rear Hub/Bearing From Axle
7. Remove the hub/bearing from the rear axle and brake support plate.
INSTALL
1. Install the 4 hub/bearing to axle mounting bolts into the holes in the flange of the rear axle. 2.
Install the rear brake support plate on the 4 mounting bolts installed in the flange of the rear axle. 3.
Align the rear hub/bearing with the 4 mounting bolts and start mounting bolts into hub/bearing.
Tighten the 4 bolts in a criss-cross pattern until the
hub/bearing and brake support plate is fully and squarely seated onto flange of rear axle.
4. Tighten the 4 hub/bearing mounting bolts to a torque of 129 Nm (95 ft. lbs.). 5. Install the rear
wheel speed sensor on the rear hub/bearing flange. Install the speed sensor attaching bolt and
tighten to a torque of 12 Nm (105
inch lbs.).
6. Install brake drum on hub/bearing. 7. Install wheel and tire. 8. Tighten the wheel stud nuts in the
proper sequence to a torque of 129 Nm (95 ft. lbs.). 9. Adjust the rear brakes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Hub > Axle Nut > Component
Information > Specifications
Axle Nut: Specifications
FRONT:
To Hub Bearing Nut .............................................................................................................................
............................................ 183 Nm (135 ft. lbs.)
REAR:
Stub Axle Nut .......................................................................................................................................
............................................ 224 Nm (180 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence
Wheel Fastener: Specifications Wheel Tightening Sequence
Wheel Torque Sequence - Master
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence > Page 6962
Wheel Fastener: Specifications Lug Nut Torque
Lug Nut Torque ....................................................................................................................................
................................ 110 - 135 Nm (85 - 115 ft. lbs.) Hex Size ...........................................................
...........................................................................................................................................................
19 mm
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Wheel Tightening Sequence > Page 6963
Wheel Fastener: Specifications Wheel Stud Size
Mounting Stud Size .............................................................................................................................
........................................................... M12 x 1.5 mm
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Specifications > Page 6964
Wheel Fastener: Description and Operation
The wheel studs and nuts are designed for the specific wheel applications used on a vehicle and
must be replaced with equivalent parts.
If wheel attaching studs need to be replaced in the hub and bearing assembly the studs CAN NOT
be hammered out of the hub flange. If a stud is removed by hammering it out of the bearing flange,
damage to the hub and bearing assembly will occur leading to premature bearing failure.
Use the procedure and special tools shown in the service procedures section for the wheel
mounting studs when replacing the wheel attaching studs.
The hub and bearing assembly does not require removal from the steering knuckle or the rear
knuckle to replace the wheel attaching studs in the hub and bearing assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front
Wheel Fastener: Service and Repair Front
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing assembly will occur leading to premature
bearing failure.
REMOVE
The following procedure and special tools shown MUST BE used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the steering knuckle to
replace wheel attaching studs in the hub and bearing assembly. 1. Raise vehicle on jackstands or
centered on a frame contact type hoist. 2. Remove the front wheel and tire assembly from the
vehicle.
3. Remove the front caliper assembly from the front steering knuckle assembly. Refer to Brakes
and Traction Control for caliper removal
procedure.
4. Remove front rotor from hub, by pulling it straight off wheel mounting studs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 6967
5. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly, so the
threads on the stud are even with end of lug nut.
Install Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and
wheel stud.
6. Tightening down on special tool will push wheel stud out of the hub and bearing assembly
flange. When shoulder of wheel stud is past flange
remove special tool from hub and bearing assembly. Remove lug nut from stud and remove wheel
stud from flange.
INSTALL
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the braking disk back on the hub and bearing assembly. 4. Install front brake caliper back
over braking disc and align with caliper mounting holes on steering knuckle. Refer to Brakes and
Traction Control
for caliper installation procedure. Install the caliper adapter to steering knuckle attaching bolts and
torque to 19 Nm (168 inch lbs.).
5. Install wheel and tire assembly on vehicle. Tighten the wheel mounting stud nuts in proper
sequence until all nuts are torqued to half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
6. Lower vehicle to the ground.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Steering and Suspension > Wheels and Tires > Wheel Fastener > Component Information >
Service and Repair > Front > Page 6968
Wheel Fastener: Service and Repair Rear
CAUTION: If a wheel attaching stud needs to be replaced in the hub and bearing assembly the
studs CAN NOT be hammered out of the hub flange. If a stud is removed by hammering it out of
the bearing flange, damage to the hub and bearing assembly will occur leading to premature hub
and bearing failure.
REMOVE
The following procedure and special tools shown MUST be used when replacing wheel attaching
studs. The hub and bearing assembly does not require removal from the rear axle for replacement
of the wheel attaching studs. 1. Raise vehicle on jackstands or centered on a frame contact type
hoist. 2. Remove the rear wheel and tire assembly. 3. Remove the rear brake drum.
4. Install a lug nut on the wheel stud to be removed from the hub and bearing assembly so the
threads on stud are even with end of lug nut. Install
Remover, Special Tool C-4150A, or equivalent on hub and bearing assembly flange and wheel
stud.
5. Tightening down on special tool will push wheel stud out of the hub and bearing assembly
flange. Remove lug nut from stud and remove wheel
stud from flange.
INSTALL
1. Install replacement wheel stud into flange of hub and bearing assembly. Install washers on
wheel stud, then install a wheel lug nut on stud with flat
side of lug nut against washers.
2. Tighten the wheel lug nut, pulling the wheel stud into the flange of the hub and bearing
assembly. When the head of the stud is fully seated against
the bearing flange, remove lug nut and washers from wheel stud.
3. Install the rear brake drum on the hub and bearing assembly. 4. Install wheel and tire assembly
on vehicle. Tighten the wheel mounting stud nuts in proper sequence until all nuts are torqued to
half specification.
Then repeat the tightening sequence to the full specified torque of 129 Nm (95 ft. lbs.).
5. Lower vehicle to the ground.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Conditioning Switch > Component Information > Description
and Operation
Air Conditioning Switch: Description and Operation
SYSTEM OPERATION
HVAC Mounted Switch
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Description and Operation > Blend/Passenger Actuator
Air Door Actuator / Motor: Description and Operation Blend/Passenger Actuator
The Blend/Passenger Actuator can move the temperature door in two directions. When the voltage
at Pin 12 of the control module is high, about 11.5 volts, and the voltage at Pin 17 is low, about 1.5
volts, the door will move towards the Heat position. When Pin 17 is High and Pin 12 is Low the
door will move towards the Cold position. When both Pins are high or both Pins are low, the
actuator will not move. The Blend/Passenger feedback signal is a voltage signal that is supplied by
the actuator to the control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the
Cold position. As the position of the Blend/Passenger actuator changes, so will the feedback
signal. The feedback signal is necessary for the correct positioning of the temperature door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Description and Operation > Blend/Passenger Actuator > Page 6978
Air Door Actuator / Motor: Description and Operation Driver Actuator
The Driver Actuator can move the temperature door in two directions. When the voltage at Pin 15
of the control module is high, about 11.5 volts, and the voltage at Pin 13 is low, about 1.5 volts the
door will move towards the Cold position. When Pin 13 is High and Pin 15 is Low the door will
move towards the Heat position. When both Pins are high or when both Pins are low, the actuator
will not move. The Driver feedback signal is a voltage signal that is supplied by the actuator to the
control. The signal will be about 4.0 volts in the Heat position and 1.0 volt in the Cold position. As
the position of the Driver Actuator changes, so will the feedback signal. The feedback signal is
necessary for the correct positioning of the temperature door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test
Air Door Actuator / Motor: Testing and Inspection Actuator Calibration/Diagnostics and Cool Down
Test
GENERAL INFORMATION
If the HVAC control module is replaced, the Calibration Diagnostic and Cool-down tests will need to
be performed. Once this group of tests have successfully passed, they can be performed
individually. The engine must be running during the test to provide hot coolant for the heater, A/C
compressor operation and to assure that the actuators are calibrated correctly The HVAC control
module is capable of troubleshooting the system in approximately 120 seconds. If a condition is
detected, an error code is displayed. The error code cannot be erased until the condition is
repaired and the diagnostic test is performed. Check wire before replacing components.
CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to
limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out
of calibration.
ACTUATOR CALIBRATION
Radio Bezel And HVAC Control
Radio Bezel And HVAC Control, Rear Blower Motor Switch And Zone Control
Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the
actuators, HVAC control module and its linkages. In vehicle calibration can be entered from the
control's front panel. If the REAR WIPE and INTERMITTENT LED's flash simultaneously when
Ignition is cycled ON, the actuators have not been calibrated or during the previous calibration a
failure occurred. Diagnostics will always occur during Calibration Diagnostic and Cool-down test.
DIAGNOSTICS
During the Actuator calibration, diagnostics are performed on the actuators and evaporator
temperature Fin Sensor. Once diagnostics are completed the REAR WIPER and INTERMITTENT
LED's will flash to indicate either a successful calibration or the appropriate fail code(s). At this time
manual testing of the Blend, Mode and Driver (if equipped) potentiometers can be performed. If a
failure is detected during Diagnostics a fault will be set in the control. When Ignition is cycled OFF
and then ON or Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash
simultaneously showing that a failure has occurred. The control will not indicate the fail code, but
only that a failure had occurred during the last diagnostics test. The only way to clear the failure
codes is repeat the Calibration Diagnostic and Cool-down test, after all repairs are
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test > Page 6981
completed.
COOL-DOWN TEST
This test has been designed for performance testing of the A/C system at the manufacturing
facility. If the HVAC control module is replaced, the Cool-down test will occur during Calibration
test. Cool-down will not occur on Heater Only units. During the Cool-down test the control will
monitor the temperature of the Fin Sensor. The A/C system must be able to bring the evaporator
temperature down a predetermined minimum amount in less than 2 minutes.
Calibration/Cooldown LED Display Codes
CALIBRATION COOL-DOWN LED DISPLAY CODES
See table for definition of flashing LED's. If no problems are found, the control functions normally.
CALIBRATION/DIAGNOSTICS TEST ENTRY
To Initiate Tests: Set Blower motor ON HIGH
- Set Mode position to Panel
- Open all A/C outlets
- Set Temperature to Cold (Both slide pots if equipped)
- Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light)
Results: All LED's will turn on for 5 Seconds
- Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing.
Cool-down test is running if A/C and RECIRC are alternately flashing.
- Acceptable results is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit.
- After all tests have passed, Calibration Diagnostics and Cool-down can be run separately
COOL-DOWN TEST ENTRY
To Initiate Tests: Set Blower motor ON HIGH
- Set Mode position to Panel
- Open all A/C outlets
- Set Temperature to Cold (Both slide pots if equipped)
- Depress WASH and A/C simultaneously for 5 Seconds
NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct,
operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test > Page 6982
Results: All LED's will turn on for 5 Seconds
- Cool-down Test is running when A/C and RECIRC. are alternately flashing. If A/C and RECIRC.
are flashing simultaneously, Cool-down has failed.
CALIBRATION DIAGNOSTICS AND COOL-DOWN ABORT
Test can be aborted by doing one of the following: Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons.
- Cycling Ignition OFF and then ON.
- Control will automatically abort after 15 minutes from the time Calibration Diagnostics and
Cool-down was entered.
The HVAC control module will return to normal operation or may indicate unsuccessful Calibration
Diagnostics or Cool-down test by LED's flashing simultaneously.
EEPROM DATA
Calibration Diagnostics, Cool-down Status and evaporator temperature Fin Sensor values are
stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control
module uses this information: To determine if Cool-down needs to run
- For proper position of the Heater-A/C unit assembly doors
ACTUATOR CALIBRATION AND DIAGNOSTICS
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module.
Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and
INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend
actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated
the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as
actuator travel falling within their minimum and maximum limits.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Actuator Calibration/Diagnostics and Cool Down Test > Page 6983
Air Door Actuator / Motor: Testing and Inspection Mode Actuator Background
The Mode actuator can move the mode door in two directions. When the voltage at Pin 18 of the
control module is high, about 11.5 volts, and the voltage at Pin 12 is low, about 1.5 volts the door
will move towards the Panel position. When Pin 12 is High and Pin 18 is Low the door will move
towards the Defrost position. When both Pin are high or when both Pins are low, the actuator will
not move. The Mode door feedback signal is a voltage signal that is supplied by the actuator to the
control. The signal will be about 4.5 volts in the Panel position and 0.5 volts in the Defrost position.
As the position of the Mode actuator changes, so will the feedback signal. The feedback signal is
necessary for the correct positioning of the mode door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Testing and Inspection > Page 6984
Air Door Actuator / Motor: Adjustments
1. Install lower FLOOR door actuator gear to housing. Match master spline of FLOOR door
actuator gear to master spline on door. 2. Install cam wheel. Align cam wheel track to FLOOR door
actuator gear. 3. Align cam wheel slot with the post on the distribution housing marked "1". 4.
Install PANEL door actuator gear. Align master spline of PANEL door actuator gear to master
spline on PANEL door. Position actuator gear
within cam wheel track.
5. Install DEFROST door actuator gear to housing. Match master spline of DEFROST door
actuator to master spline on DEFROST door. Position
actuator gear within cam wheel track.
6. Reinstall housing in vehicle. 7. Perform the HVAC control Calibration Diagnostic and Cool-down
test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement
Air Door Actuator / Motor: Service and Repair Blend Door Actuator Replacement
REMOVAL
Side View Of HVAC With Actuators
The air conditioning system can be equipped with either a standard, single blend-air door actuator,
or it can be equipped with dual actuators. The dual system has separate blend-air controls. This
allows for separate control of the driver's side air, and the passenger side air.
1. Remove the lower left side steering column cover.
ABS Control Module
2. Remove ABS control module. 3. Remove blend-air actuator connector.
Blend Air Actuator
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6987
4. Remove blend-air actuator.
INSTALLATION
1. For installation, reverse the above procedures. 2. Perform the HVAC Control Calibration
Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6988
Air Door Actuator / Motor: Service and Repair Recirculation Air Door Actuator Replacement
REMOVAL
1. Pull back on carpeting on the right lower floor. 2. Remove Recirc door actuator connector.
Recirculation Door Actuator
3. Remove (3) mounting screws for Recirc actuator. 4. Remove Recirc actuator. 5. Disengage
actuator linkage at Recirc door. 6. Remove actuator from vehicle.
INSTALLATION
1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration
Diagnostic and Cool-down test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6989
Air Door Actuator / Motor: Service and Repair Front Heat A/C
The content of this article reflects changes called for in TSB 26-06-98.
REMOVAL
1. Remove the Instrument Panel. See: Instrument Panel, Gauges and Warning
Indicators/Instrument Cluster / Carrier/Service and Repair
ABS Control Module
2. Remove ABS control module.
Mode Door Actuator Connector
3. Remove mode actuator connector.
Mode Door Actuator
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6990
4. Remove mode door actuator.
INSTALLATION
1. For installation, reverse the above procedures. 2. Perform the HVAC control Calibration
Diagnostic and Cool-down test. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Door, HVAC > Air Door Actuator / Motor, HVAC >
Component Information > Service and Repair > Blend Door Actuator Replacement > Page 6991
Air Door Actuator / Motor: Service and Repair Rear Heat A/C
REMOVAL
1. Remove A/C unit. 2. Place unit on bench. 3. Remove mode door actuator connector. 4. Remove
mode door actuator mounting screws and remove actuator.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Description and Operation
Air Duct: Description and Operation
SYSTEM OPERATION
The air distribution ducts for the A/C, Heater, Defroster, and Second Seating Air Distribution are not
serviceable in vehicle.
The only ducts that are serviceable in the vehicle are the side window demister ducts and the ducts
that feed the front door outlets for the first rear passenger(s) seating.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement
Air Duct: Service and Repair Air Distribution Duct (A/C) Replacement
REMOVAL
Quarter Trim Panel
1. Remove quarter trim panel, D-pillar, and headliner. 2. Remove screws securing D-pillar duct to
quarter panel. Pull duct up and away from unit.
Rear Crossover Duct
3. Remove screws securing duct to rear header.
Upper A/C Duct
4. Remove screws securing duct to right and left rails.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement > Page 6997
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement > Page 6998
Air Duct: Service and Repair Air Distribution Duct (Heater) Replacement
REMOVAL
Quarter Trim Panel
Rear Heat - A/C Unit
1. Remove quarter trim panel and D-pillar. 2. Remove screws securing lower heat duct to housing.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Air Duct > Component Information > Service and Repair > Air
Distribution Duct (A/C) Replacement > Page 6999
Air Duct: Service and Repair Side Window Demister Duct Replacement
Left Side Demister Duct
LEFT SIDE
The LEFT side window demister duct is a two piece design. The left side has a long duct that
attaches to an intermediate duct and then to the distribution housing. The duct is located on top of
the instrument panel. To service the duct, remove the I/P cover and remove duct
retainers/fasteners.
Right Side Demister Duct
RIGHT SIDE
The demister duct on the right side is a one piece design. It is one long duct that attaches to the
distribution housing. The duct is located on top of the instrument panel and it is not serviceable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Ambient Temperature Sensor / Switch HVAC > Component
Information > Service and Repair
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
1. Raise and support vehicle on safety stands. 2. From behind front bumper fascia, remove screw
holding sensor to radiator closure panel. 3. Remove sensor from vehicle.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and
Inspection > Flow of Diagnosis
Blower Motor Noise/Vibration Diagnosis
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Testing and
Inspection > Flow of Diagnosis > Page 7007
Blower Motor: Component Tests and General Diagnostics
VIBRATION AND/OR NOISE DIAGNOSIS
The blower speed switch, in conjunction with the resistor block, supplies the blower motor with
varied voltage.
CAUTION: Stay clear of the blower motor and resistor block (Hot). Do not operate the blower motor
with the resistor block removed from the heater A/C housing.
Blower Motor Noise/Vibration Diagnosis
Refer to the Blower Motor Vibration/Noise chart for diagnosis.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement
Blower Motor: Service and Repair Blower Motor and Wheel Assembly Replacement
REMOVAL
1. Remove glove box.
Blower Motor Cover
2. Remove (4) hex head screws to blower motor cover. 3. Disconnect blower motor wiring.
Wiring Grommet
Feeding Wiring Through Housing
4. Remove grommet for wiring. Feed wiring through blower housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement > Page 7010
Blower Motor Screws
5. Remove mounting screws for blower motor. 6. Allow the blower assembly to drop down, and
remove assembly from vehicle.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement > Page 7011
Blower Motor: Service and Repair Blower Motor Wheel Replacement
The blower motor wheel is not serviced separately If the wheel needs to be replaced it is serviced
as an assembly of the blower motor. For service procedure information, refer to Blower Motor
Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor > Component Information > Service and Repair >
Blower Motor and Wheel Assembly Replacement > Page 7012
Blower Motor: Service and Repair Rear Blower Motor Replacement
REMOVAL
1. Remove the right quarter trim panel and D-pillar trim.
Blower Motor
2. Remove (5) screws securing the blower motor housing to the rear of the HVAC housing (one
screw located on evaporator cover). 3. Twist motor out of scroll housing. 4. Disconnect blower
motor wiring connector.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Front Blower Motor Relay
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Locations >
Front Blower Motor Relay > Page 7017
Blower Motor Relay: Locations Rear Blower Relay
Rear Blower Motor Relay
This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation > Front Blower Motor Relay
Blower Motor Relay: Description and Operation Front Blower Motor Relay
Circuit Operation
Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the
HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1.
The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power
Distribution Center (PDC).
The coil side of the relay is energized when the ignition switch is in the RUN position only. Power
for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the
relay
Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit
A22.
Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl
panel.
Ground for the blower motor is controlled through the blower motor resistor and the blower motor
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Relay > Component Information > Description
and Operation > Front Blower Motor Relay > Page 7020
Blower Motor Relay: Description and Operation Rear Blower Relay
Circuit Operation
Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp
fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear
blower motor passes through the temperature sensor and one or more resistors, depending on
speed selection.
Two switches operate the rear blower motor by supplying ground; the front control switch and the
rear control switch. The front control switch must be in the ON position for the rear control switch to
operate the rear blower motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description
and Operation
Blower Motor Resistor: Description and Operation
SYSTEM OPERATION
The rear blower motor resistor is not serviceable separately. The resistor is integral to the blower
motor. If resistor is faulty, it is necessary to replace the complete blower motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description
and Operation > Page 7024
Blower Motor Resistor: Service and Repair
REMOVAL
1. Open hood. 2. Disconnect and isolate negative battery cable.
Resistor Block Location
3. Locate and remove the wire connector from the blower resistor block. Block is located at the
back of the engine compartment on the passenger
side of the vehicle under the wiper module.
NOTE: It may not necessary to remove the wiper module to access the resistor block.
Resistor Block Removal
4. Using a long flat blade screwdriver, gently push in on drivers side of resistor. Be careful to catch
the inner release tang and gently pry outward.
WARNING: THE RESISTOR BLOCK MAY BE HOT. DO NOT ATTEMPT TO SERVICE THE
RESISTOR BLOCK IF THE SYSTEM HAS BEEN RUNNING RECENTLY. LET THE SYSTEM
COOL DOWN BEFORE REPAIRS ARE INITIATED.
5. Remove resistor block by inserting a flat blade pry tool on the side of the resistor block and
pushing inward. Two guide lines are shown on the
right hand edge of the resistor block to help guide the blade position. This will release the clips on
the side of the resistor block. Pull resistor block out.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Resistor > Component Information > Description
and Operation > Page 7025
INSTALLATION
- For installation, reverse the above procedures. Make sure the "TOP" lettering is on the top of the
resistor. The coils on the Resistor Block should not be contacting one another. Before installation,
gently separate the coils (with fingers only) if one coil is contacting another.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Blower Motor Switch > Component Information > Description
and Operation
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
The rear blower speed switch controls the rear blower with the choice of low and high speeds.
When the switch is on it allows the blower speed switch located on the rear headliner to control
rear blower speed. This switch will override the rear headliner blower switch. For operation
instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from
the A/C control module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications
Compressor Clutch: Specifications
Clutch Air Gap .....................................................................................................................................
........................... 0.41 - 0.79 mm (0.016 - 0.031 in.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch > Component
Information > Specifications > Page 7033
Compressor Clutch: Service and Repair
REMOVAL and INSTALLATION
After a new clutch has been installed, check the voltage and amperage to the clutch (determine it
to be satisfactory). Then cycle the A/C clutch approximately 20 times (5 sec. on and 5 sec. off). For
this procedure, set the system to the A/C mode, using high blower, and engine rpm at 1500-2000.
This procedure (burnishing) will seat the opposing friction surfaces and provide a higher clutch
torque capability.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Testing and Inspection
Compressor Clutch Coil: Testing and Inspection
The air conditioning compressor clutch electrical circuit is controlled by the Powertrain Control
Module. It is located in the engine compartment outboard of the battery.
If the compressor clutch does not engage verify refrigerant charge.
If the compressor clutch still does not engage check for battery voltage at the pressure transducer
located on the liquid line. If voltage is not detected, refer to Powertrain Management/Computer and
Control Systems/Powertrain Diagnostic Procedures for diagnostic information.
If voltage is detected at the pressure transducer connect pressure transducer and check for battery
voltage between the compressor clutch connector terminals.
If voltage is detected, perform A/C Clutch Coil Tests.
Tests 1. Verify battery state of charge. (Test indicator in battery should be green). 2. Connect an
ammeter (0-10 ampere scale) in series with the clutch coil terminal. Use a voltmeter (0-20 volt
scale) with clip leads measuring
voltage across the battery and A/C clutch.
3. With A/C control in A/C mode and blower at low speed, start the engine and run at normal idle.
4. The A/C clutch should engage immediately and the clutch voltage should be within two volts of
the battery voltage. If the A/C clutch does not
engage, test the fuse.
5. The A/C clutch coil is acceptable if the current draw is 2.0 to 3.7 amperes at 11.5-12.5 volts at
clutch coil. This is with the work area
temperature at 21 degree Celsius (70 degree Fahrenheit). If voltage is more than 12.5 volts, add
electrical loads by turning on electrical accessories until voltage reads below 12.5 volts.
6. If coil current reads zero, the coil is open and should be replaced. If the ammeter reading is 4
amperes or more, the coil is shorted and should
be replaced. If the coil voltage is not within two volts of the battery voltage, test clutch coil feed
circuit for excessive voltage drop.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Testing and Inspection > Page 7037
Compressor Clutch Coil: Service and Repair
REMOVAL
Compressor Shaft Bolt And Clutch Plate
1. Remove the compressor shaft bolt. A band type oil filter removal tool can be placed around the
clutch plate to aid in bolt removal.
CAUTION: Do not use screwdrivers between the clutch plate assembly and pulley to remove front
plate as this may damage the front plate assembly.
Clutch Plate And Shims
2. Tap the clutch plate with a plastic hammer and remove clutch plate and shim.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Testing and Inspection > Page 7038
Removing Pulley Snap Ring
3. Remove pulley retaining snap ring with snap ring pliers (C-4574), and slide pulley assembly off
of compressor. 4. Remove coil wire clip screw and wire harness.
Clutch Coil Snap Ring
5. Remove snap ring retaining field coil onto compressor housing. Slide field coil off of compressor
housing. 6. Examine frictional faces of the clutch pulley and front plate for wear. The pulley and
front plate should be replaced if there is excessive wear or
scoring. If the friction surfaces are oily, inspect the shaft nose area of the compressor for oil and
remove the felt from the front cover. If the compressor felt is saturated with oil, the shaft seal is
leaking and will have to be replaced.
7. Check bearing for roughness, excessive leakage or grease. If grease from bearing has
contaminated the faces of the pulley or front plate, they
should be replaced. If the bearing is rough or binds, replace clutch pulley and front plate assembly.
CAUTION: The clutch pulley and the front plate were mated at the factory by a burnishing
operation. No attempt should be made to separately replace either part. This will result in clutch
slippage due to insufficient contact area.
INSTALLATION
1. Align pin in back of field coil with hole in compressor end housing, and position field coil into
place. Make sure that lead wires are properly
routed, and fasten with the wire clip screw.
2. Install field coil retaining snap ring with snap ring pliers. The bevel side of the snap ring facing
outward. Also both snap ring eyelets must be to the
right or left of the pin on compressor. Press snap ring to make sure it is properly seated in the
groove.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor HVAC > Compressor Clutch Coil > Component
Information > Testing and Inspection > Page 7039
CAUTION: If snap ring is not fully seated it will vibrate out, resulting in a clutch failure and severe
damage to the front face of the compressor.
Installing Pulley Assembly
3. Install pulley assembly to compressor. If necessary, tap gently with a block of wood on the
friction surface.
CAUTION: Do not mar the pulley frictional surface.
4. Install pulley assembly retaining snap ring (bevel side outward) with snap ring pliers. Press the
snap ring to make sure it is properly seated in the
groove.
5. If the original front plate assembly and pulley assembly are to be reused, the old shim(s) can be
used. If not, place a trial stack of shims, 1 mm
(0.040 in.) thick, on the shaft against the shoulder.
6. Install front plate assembly onto shaft. 7. With the front plate assembly tight against the shim(s),
measure the air gap between front plate and pulley face with feeler gauges. The air gap
should be between 0.5 and 0.9 mm (0.020 and 0.035 inch) If proper air gap is not obtained, add or
subtract shims until desired air gap is obtained.
8. Install compressor shaft bolt. Tighten to 17.5 +/-2 N.m (155 +/- 20 in. lbs.).
NOTE: Shims may compress afier tightening shaft nut. Check air gap in four or more places to
verify if air gap is still correct. Spin pulley for final check.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Component Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Compressor Clutch Relay > Component Information >
Locations > Component Locations > Page 7044
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Specifications
Condenser HVAC: Specifications
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................... 150 ml (5.0 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Front A/C Condenser
Condenser HVAC: Service and Repair Front A/C Condenser
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL 1. Recover A/C system refrigerant.
Liquid Line
2. Remove liquid line at filter-drier.
Filter Drier
3. Remove (2) bolts attaching filter-drier to radiator module. 4. Remove upper radiator
crossmember. 5. Tilt radiator rearward.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Front A/C Condenser > Page 7050
Upper Discharge Line
6. Remove upper discharge line at condenser. 7. Through fascia, remove lower liquid line from
filter-drier. 8. Remove (2) lower condenser mounting bolts. 9. Remove (2) upper mounting bolts.
Condenser Removal
10. Remove condenser from vehicle.
INSTALLATION
NOTE: Inspect Cooling Module for presence of seals. Verify seals are available for re-installation.
1. Before installation, replace all O-rings and gaskets, coat all sealing surfaces with approved
wax-free refrigerant oil. Then, reverse the above
procedures.
2. Torque the following components to specifications:
- Liquid line at filter/drier - 45 in. lbs. +/- 10.
- Upper discharge line at condenser - 180 in. lbs +/- 20
- Lower liquid line to condenser - 180 in. lbs +/- 20.
- (2) lower, condenser mounting bolts - 45 in. lbs +/- 10.
- (2) upper, condenser mounting bolts - 45 in. lbs +/- 10.
3. Evacuate and charge system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Condenser HVAC > Component Information > Service and
Repair > Front A/C Condenser > Page 7051
Condenser HVAC: Service and Repair Rear A/C Auxiliary Condenser
In vehicles equipped with rear heater and air conditioning, it will be equipped with an auxiliary
condenser. The auxiliary condenser is mounted on the primary condenser in front of the radiator.
Both condenser must be removed as an assembly and then separated.
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
NOTE: Special effort must be used to keep all R-134a system components moisture-tree. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
The condenser assembly must first be removed from vehicle. Refer to CONDENSER ASSEMBLY
removal and installation.
REMOVAL 1. After condenser assembly removal, place on bench for disassembly. 2. Remove (1)
bolt to liquid line on auxiliary condenser.
Rear Heat - A/C Auxiliary Condenser
3. Remove (4) attaching bolts and separate auxiliary from primary condenser.
INSTALLATION 1. Before installation, replace all O-rings and gaskets. Coat all sealing surfaces
with approved wax free refrigerant oil. Then, reverse the above
procedures.
2. Evacuate and recharge system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations
Control Assembly: Locations
HVAC Control Module
The control module is included in the A/C control head located on the instrument panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 7055
Control Assembly: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 7056
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 7057
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information >
Locations > Page 7058
Control Assembly: Description and Operation
HVAC Control Module
HVAC Control Module
The HVAC control module regulates the operation of the various actuator motors. The actuator
motors are used to move the mode, blend-air, and Recirculation doors.
The control module is included in the A/C control head located on the instrument panel. The control
head includes the blower speed switch, rear wiper and washer operation, front & rear window
defogger, recirculation door operation, and A/C compressor operation if equipped.
NOTE: The Recirculation function on the HVAC control module automatically defaults to the OFF
position after a ignition key cycle. To reactivate the Recirculation function, the Recirculation button
must be repressed.
NOTE: The rear blower speed switch is serviced separately from the control head.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit
Control Assembly: Testing and Inspection Calibration -- May Be Needed After Replacing Control
Unit
Actuator Calibration/Diagnostics and Cool-down Test
GENERAL INFORMATION
If the Heating Ventilation and Air Conditioning (HVAC) control module is replaced, the Calibration
Diagnostic and Cool-down tests will need to be performed. Once this group of tests have
successfully passed, they can be performed individually. The engine must be running during the
test to provide hot coolant for the heater, A/C compressor operation and to assure that the
actuators are calibrated correctly. The HVAC control module is capable of troubleshooting the
system in approximately 120 seconds. If a condition is detected, an error code is displayed. The
error code cannot be erased until the condition is repaired and the diagnostic test is performed.
Check wiring before replacing components.
CAUTION: Do not remove the actuators from the Heater-A/C unit assembly with power applied.
Removal should only be done with the Ignition OFF. The actuators have no mechanical stops to
limit the travel. If the actuator rotates and is not connected to the unit assembly, it will become out
of calibration.
Radio Bezel and HVAC Control
Radio Bezel and HVAC Control w/Rear Blower and Zone Control
ACTUATOR CALIBRATION
Mode, Blend and Zone (if equipped) door calibration compensates for mechanical variations in the
actuators, HVAC control module and its
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7061
linkages. In vehicle calibration can be entered from the control's front panel. If the REAR WIPE and
INTERMITTENT LED's flash simultaneously when Ignition is cycled ON, the actuators have not
been calibrated or during the previous calibration a failure occurred. Diagnostics will always occur
during Calibration Diagnostic and Cool-down test.
DIAGNOSTICS
During the Actuator calibration, diagnostics are performed on the actuators and evaporator
temperature Fin Sensor.
Once diagnostics are completed the REAR WIPER and INTERMITTENT LED's will flash to indicate
either a successful calibration or the appropriate fail code(s). At this time manual testing of the
Blend, Mode and Driver (if equipped) potentiometers can be performed. If a failure is detected
during Diagnostics a fault will be set in the control. When Ignition is cycled OFF and then ON or
Diagnostics is aborted, the REAR WIPER and INTERMITTENT LED's will flash simultaneously
showing that a failure has occurred. The control will not indicate the fail code, but only that a failure
had occurred during the last diagnostics test. The only way to clear the failure codes is repeat the
Calibration Diagnostic and Cool-down test, after all repairs are completed.
COOL-DOWN TEST
This test has been designed for performance testing of the A/C system at the manufacturing
facility. If the HVAC control module is replaced, the Cool-down test will occur during Calibration
test. During the Cool-down test the control will monitor the temperature of the Fin Sensor. The A/C
system must be able to bring the evaporator temperature down a predetermined minimum amount
in less than 2 minutes.
NOTE: Cool-down will not occur on Heater Only units.
CALIBRATION/COOL-DOWN LED DISPLAY CODES
Calibration/Cooldown Test LED's
NOTE: See chart for definition of flashing LED's. If no problems are found, the control functions
normally.
CALIBRATION/DIAGNOSTICS TEST ENTRY
TO INITIATE TESTS:
- Set Blower motor ON HIGH
- Set Mode position to Panel
- Open all A/C outlets
- Set Temperature to Cold (Both slide pots if equipped)
- Depress WASH and REAR WIPER button simultaneously for 5 Seconds (Until all LED's light)
RESULTS:
- All LED's will turn on for 5 Seconds
- Calibration Test is running when REAR WIPER and INTERMITTENT are alternately flashing.
Cool-down test is running if A/C and RECIRC are alternately flashing.
- Acceptable result is REAR WIPER LED is the only LED flashing. Push Rear Wiper to exit.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7062
- After all tests have passed, Calibration Diagnostics and Cool-down can be run separately.
COOL DOWN TEST ENTRY
NOTE: Prior to start of test, If the evaporator is already cold, the system will fail test. To correct,
operate system with A/C OFF and the blower motor ON high for three minutes prior to starting test.
TO INITIATE TESTS:
- Set Blower motor ON HIGH
- Set Mode position to Panel
- Open all A/C outlets
- Set Temperature to Cold (Both slide pots if equipped)
- Depress WASH and A/C simultaneously for 5 Seconds
RESULTS:
- All LED's will turn on for 5 Seconds
- Cool-down Test is running when A/C and RECIRC are alternately flashing. If A/C and RECIRC
are flashing simultaneously, Cool-down has failed.
CALIBRATION DIAGNOSTICS AND COOL-DOWN ABORT
Test can be aborted by doing one of the following: Depressing Rear Window Defogger, RECIRC and Rear Wiper buttons.
- Cycling Ignition OFF and then ON.
- Control will automatically abort after 15 minutes from the time Calibration Diagnostics and
Cool-down was entered.
The HVAC control module will return to normal operation or may indicate unsuccessful Calibration
Diagnostics or Cool-down test by LED's flashing simultaneously.
EEPROM DATA
Calibration Diagnostics, Cool-down Status and evaporator temperature Fin Sensor values are
stored in an EEPROM memory internal to the control. The microcomputer within the HVAC control
module uses this information: To determine if Cool-down needs to run
- For proper position of the Heater-A/C unit assembly doors
ACTUATOR CALIBRATION AND DIAGNOSTICS
NOTE: Do not run actuators unless they are properly mounted on the HVAC control module.
Actuator end point calibration takes approximately 60 seconds. The REAR WIPER and
INTERMITTENT LED's will flash alternately during the test. The control will cycle the Blend
actuator(s) to the Heat stop first then back to Cold. After the Blend actuator(s) have been calibrated
the Mode actuator will be cycled to Defrost and then to Panel. Successful calibration is defined as
actuator travel falling within their minimum and maximum limits.
Blend/Passenger Actuator Background The Blend/Passenger Actuator can move the temperature
door in two directions. When the voltage at Pin 12 of the control module is high, about 11.5 volts,
and the voltage at Pin 17 is low, about 1.5 volts, the door will move towards the Heat position.
When Pin 17 is High and Pin 12 is Low the door will move towards the Cold position. When both
Pins are high or both Pins are low, the actuator will not move. The Blend/Passenger feedback
signal is a voltage signal that is supplied by the actuator to the control. The signal will be about 4.0
volts in the Heat position and 1.0 volt in the Cold position. As the position of the Blend/Passenger
actuator changes, so will the feedback signal. The feedback signal is necessary for the correct
positioning of the temperature door.
Driver Actuator Background The Driver Actuator can move the temperature door in two directions.
When the voltage at Pin 15 of the control module is high, about 11.5 volts, and the voltage at Pin
13 is low, about 1.5 volts the door will move towards the Cold position. When Pin 13 is High and
Pin 15 is Low the door will move towards the Heat position. When both Pins are high or when both
Pins are low, the actuator will not move. The Driver feedback signal is a voltage signal that is
supplied by the actuator to the control. The signal will be about 4.0 volts in the Heat position and
1.0 volt in the Cold position. As the position of the Driver Actuator changes, so will the feedback
signal. The feedback signal is necessary for the correct positioning of the temperature door.
Mode Actuator Background The Mode actuator can move the mode door in two directions. When
the voltage at Pin 18 of the control module is high, about 11.5 volts, and the voltage at Pin 12 is
low, about 1.5 volts the door will move towards the Panel position. When Pin 12 is High and Pin 18
is Low the door will move towards the Defrost position. When both Pin are high or when both Pins
are low, the actuator will not move. The Mode door feedback signal is a voltage signal that is
supplied by the actuator to the control. The signal will be about 4.5 volts in the Panel position and
0.5 volts in the Defrost position. As the position of the Mode actuator changes, so will the feedback
signal. The feedback signal is necessary for the correct positioning of the mode door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7063
FAIL CODES/LEVEL DISPLAY
Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LED's flashing in
sequence. The REAR WIPER LED represents the Level and the INTERMITTENT LED represents
the Value. After Calibration/Diagnostics is completed, the control will begin flashing Level 1 codes.
Depressing the WASH button will cycle to Level 2, depressing WASH again will cycle to Level 3.
Each time the WASH button is depressed will cycle to the next level. After Level 5 is reached, you
will cycle back to Level 1.
Failure Code Levels -- Wipe Button LED
Level Display
1 Fail Codes
2 Mode Potentiometer Test
3 Blend/Pass. Potentiometer Test
4 Evaporator Probe (A/C and Zone Units Only)
5 Driver Potentiometer (Zone Units Only)
Level 1 Failure Codes -- Intermittent Wipe Button LED
Code Definition
0 Passed ALL Tests
1 Mode Actuator Did Not Reach Defrost Position
2 Mode Actuator Did Not Reach Panel Position
3 Blend/Pass Actuator Did Not Reach Cold Stop
4 Blend/Pass Actuator Did Not Reach Heat Stop
5 Evaporator Probe Open
6 Evaporator Probe Shorted
7 Driver Actuator Did Not Reach Cold Stop
8 Zone/Driver Actuator Did Not Reach Heat Stop
9 Control Head Internal Failure
NOTE: If the Control is a Heater Only you will only cycle from Levels 1 to 3.
TEMPERATURE AND MODE POTENTIOMETER DIAGNOSTICS
A/C Units The Temperature and Mode Potentiometer can be tested after calibration is complete by
pressing the WASH button and cycling to Levels 2, 3 or 5 as displayed by the REAR WIPER LED.
INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is moved
from one end to the other.
Heater Only Units On Heater Only units you can only cycle to Levels 2 and 3. In each individual
test the INTERMITTENT LED flash rate will change as the Temperature or Mode potentiometer is
moved from one end to the other.
EVAPORATOR PROBE TEMPERATURE DIAGNOSTICS
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following: Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
Display Sequence is as follows: REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one's digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cool-down test is exited.
A/C and Recirc LED's Flashing Simultaneously
FAILED COOL-DOWN TEST.
1. Determine if the refrigerant system is operating correctly:
- Check the outlet air temperature
- Feel the compressor suction plumbing, is it hot?
2. If not OK, go to Step 3. If OK, repeat the Calibration Diagnostic and Cool-down test. 3. If system
does not seem to be operating correctly, perform diagnostics for poor performance:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7064
- Low refrigerant charge
- No charge
- Compressor not operating
COOL-DOWN TEST
Verify that the test was done with the evaporator at room temperature. The test consists of starting
the compressor and measuring the time it takes for the evaporator temperature to fall 7°C (20°F). If
the compressor has been running, the evaporator is cold already and will not be capable of falling
7°C (20°F). If the test was run with a cold evaporator, turn A/C off and turn the blower motor switch
to high position for 3 to 5 minutes till the evaporator is to room temperature. Then repeat the
Calibration Diagnostic and Cool-down test.
WON'T PASS COOL-DOWN TEST
If refrigerant system is performing properly and the system will not pass test. Repeat the
Calibration Diagnostic and Cool-down test to determine if the evaporator temperature FIN sensor
has developed an open or a short circuit. If the HVAC control module still passes Calibration test,
verify Cool-down test manually with a pocket thermometer. The outlet air temperature must drop at
least 7°C (20°F) within two minutes. If the vehicle passes with the manual thermometer, take HVAC
control to level 4 (evaporator probe temperature readout) and repeat the Cool-down test. Ensure
the evaporator is at room temperature before starting test. Check if evaporator probe will drop the
temperature 7°C (20°F) in two minutes. If the Evaporator Probe is found to be faulty, check that the
sensor is positioned in the evaporator fins properly. If not, correct and repeat test. If OK, replace
the evaporator probe.
Once the repairs are completed, repeat the Calibration Diagnostic and Cool-down test. Repeating
the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Not Flashing
The system has passed calibration. Press the Rear Wiper button to exit calibration.
Rear Wiper LED Flashing Once, Int. LED Flashing Once
THE MODE ACTUATOR DID NOT REACH DEFROST POSITION
1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from the defrost to
panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If
voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary.
2. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 3. If not OK, repair as
necessary.
3. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace
actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test.
Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Twice
THE MODE DOOR DID NOT REACH PANEL POSITION
1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from panel to defrost
position, and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If voltage is
OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary.
2. Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to
Step 3. If not OK, repair as necessary 3. Check for binding door, if door is binding repair as
necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the
Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Three Times
THE MAIN TEMPERATURE ACTUATOR ON A ZONE SYSTEM DID NOT REACH COLD STOP.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the
temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC
control from the cold
to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If
voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary
3. Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to
Step 4 If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as
necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the
Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Four Times
THE MAIN TEMPERATURE ACTUATOR ON A ZONE SYSTEM DID NOT REACH HOT STOP.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the
temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC
control from hot to
cold position and check Pin 5 voltage it should change from 3.5 - 4.5 volts 0.5 - 1.5 volts. If voltage
is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary
4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace
actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test.
Repeating the test is necessary to clear the fault codes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7065
Rear Wiper LED Flashing Once, Int. LED Flashing Five Times
THE EVAPORATOR PROBE IS OPEN.
1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If
OK, go to Step 2. If not OK, if greater than 4.75
volts check for loose or corroded connector, open circuit and repair as necessary.
2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for loose
or corroded connector, open or shorted circuit
and repair as necessary.
3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed,
press the intermittent button about 5 seconds until all LED's light to remove fault code from
memory. Then repeat the
Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Six Times
THE EVAPORATOR PROBE IS SHORTED.
1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts, If
OK, go to Step 2. If less than 0.1 volts, check for
loose or corroded connector, open or shorted circuit and repair as necessary.
2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for
shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator
Probe 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's
light to remove fault code from memory. Then repeat the
Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Seven Times
THE DRIVER'S TEMPERATURE ACTUATOR ON A ZONE SYSTEM DID NOT REACH COLD
STOP.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the
temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC
control from cold to
the hot position, check Pin 4 voltage it should changeover 0.5 - 1.5 volts 3.5 - 4.5 volts. If voltage is
OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary.
4. Check for binding doors, if door are binding repair as necessary If gears and door are OK,
replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down
test. Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Eight Times
THE DRIVER'S TEMPERATURE ACTUATOR ON A ZONE SYSTEM DUD NOT REACH HOT
STOP.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the
temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC
control from hot to
cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is OK,
go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and repair as
necessary
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary.
4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace
actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test.
Repeating the test is necessary to clear the fault codes.
Rear Wiper LED Flashing Once, Int. LED Flashing Nine Times
THE HVAC CONTROL MODULE, HAS AN INTERNAL FAILURE.
1. Replace the HVAC control module. 2. Once repairs are completed repeat the Calibration
Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
Failure Codes/Level Display
Wipe Button LED
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7066
Level 1 - Failure Code Values (Intermittent Wipe Button LED)
Fail Codes/Level are displayed using the REAR WIPER and INTERMITTENT LED's flashing in the
sequence indicated below. The REAR WIPER LED represents the Level and the INTERMITTENT
LED represents the Value. After Calibration/Diagnostics is completed, the control will begin flashing
Level 1 codes. Depressing the WASH button will cycle to Level 2, depressing WASH again will
cycle to Level 3. Each time the WASH button is depressed will cycle to the next level. After Level 5
is reached, you will cycle back to Level 1. If the Control is a Heater Only you will only cycle from
Levels 1 to 3.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7067
Control Assembly: Testing and Inspection HVAC Control Diagnostic Conditions
After calibration, Rear Wiper LED flashing once, Intermittent LED not flashing.
The system has passed calibration. Press the Rear Wiper button to exit calibration.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing once. The mode actuator
did not reach defrost position.
1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from the defrost
to panel position, and check Pin 6 voltage it should change from 0.5 - 1 volts to 3.5 - 4.5 volts. If
voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary.
2. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 3. If not OK, repair as
necessary.
3. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace
actuator. 4. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test.
Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing twice. The mode
actuator did not reach panel position.
1. Using a voltmeter, check the mode door actuator wiring connector. Check Pin 1 for battery
voltage. Move the HVAC control from panel to
defrost position, and check Pin 6 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1 volts. If
voltage is OK, go to Step 2. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary.
2. Remove actuator, and check if the gear pins are in the correct cam track or binding. If OK, go to
Step 3. If not OK, repair as necessary. 3. Check for binding door, if door is binding repair as
necessary. If gears and door are OK, replace actuator. 4. Once repairs are completed repeat the
Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing three times. The main
temperature actuator/passenger temperature actuator on a zone system did not reach cold stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the
temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC
control from the
cold to hot position, and check Pin 5 voltage it should change from 0.5 - 4 volts to 3.5 - 4.5 volts. If
voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary
3. Remove actuator, and check if gear pins are in the correct cam track or binding. If OK, go to
Step 4. If not OK, repair as necessary. 4. Check for binding door, if door is binding repair as
necessary If gears and door are OK, replace actuator. 5. Once repairs are completed repeat the
Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing four times. The main
temperature actuator/passenger temperature actuator on a zone system did not reach hot stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check the
temperature door actuator wiring connector. Check Pin 1 for battery voltage. Move the HVAC
control from hot to
cold position and check Pin 5 voltage it should change from 3.5-4.5 volts 0.5 - 1.5 volts. If voltage is
OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary
3. Remove actuator, and check if the gear pins are in the correct track on cain or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary
4. Check for binding door, if door is binding repair as necessary If gears and door are OK, replace
actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test.
Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing five times. The
evaporator probe is open.
1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If
OK, go to Step 2. If not OK, if greater than
4.75 volts check for loose or corroded connector, open circuit and repair as necessary
2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for loose
or corroded connector, open or shorted
circuit and repair as necessary
3. If ground and power circuit are OK, replace Evaporator Probe. 4. Once repairs are completed,
press the intermittent button about 5 seconds until all LED's light to remove fault code from
memory Then repeat
the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault
codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing six times. The
evaporator probe is shorted.
1. Using a voltmeter, check Pin 1 of the evaporator probe wiring connector for 0.1 - 4.75 volts. If
OK, go to Step 2. If less than 0.1 volts, check
for loose or corroded connector, open or shorted circuit and repair as necessary.
2. Using a ohmmeter, check Pin 2 for a good ground, If OK, go to Step 3. If not OK, check for
shorted circuit and repair as necessary. 3. If ground and power circuit are OK, replace Evaporator
Probe 4. Once repairs are completed, press the intermittent button about 5 seconds until all LED's
light to remove fault code from memory. Then repeat
the Calibration Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault
codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing seven times. The
Driver's temperature actuator on a zone system did not reach cold stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the
temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC
control from
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Testing
and Inspection > Calibration -- May Be Needed After Replacing Control Unit > Page 7068
cold to the hot position, check Pin 4 voltage it should change from 0.5 - 1.5 volts 3.5 - 4.5 volts. If
voltage is OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted
circuit and repair as necessary
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary.
4. Check for binding doors, if door are binding repair as necessary. If gears and door are OK,
replace actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down
test. Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing eight times. The Driver's
temperature actuator on a zone system did not reach hot stop.
1. Check if the correct HVAC control module was used. 2. Using a voltmeter, check at the
temperature door actuator wiring connector, check Pin 1 for battery voltage. Move the HVAC
control from hot
to cold position, Pin 4 voltage it should change from 3.5 - 4.5 volts to 0.5 - 1.5 volts. If voltage is
OK, go to Step 3. If not OK, check for loose or corroded connector, open or shorted circuit and
repair as necessary.
3. Remove actuator, and check if the gear pins are in the correct track on cam or if they are
binding. If OK, go to Step 4. If not OK, repair as
necessary
4. Check for binding door, if door is binding repair as necessary. If gears and door are OK, replace
actuator. 5. Once repairs are completed repeat the Calibration Diagnostic and Cool-down test.
Repeating the test is necessary to clear the fault codes.
After calibration, Rear Wiper LED flashing once, Intermittent LED flashing nine times. The HVAC
control module, has a internal failure.
1. Replace the HVAC control module. 2. Once repairs are completed repeat the Calibration
Diagnostic and Cool-down test. Repeating the test is necessary to clear the fault codes.
After calibration and testing the NC and RECIRC LED flashing simultaneously. Failed Cool-down
test.
1. Determine if the refrigerant system is operating correctly:
- Check the outlet air temperature
- Feel the compressor suction plumbing, is it hot?
2. If not OK, go to Step 3. If OK, repeat the Calibration Diagnostic and Cool-down test. 3. If system
does not seem to be operating correctly, perform diagnostics for poor performance:
- Low refrigerant charge
- No charge
- Compressor not operating
Verify that the test was done with the evaporator at room temperature. The test consists of starting
the compressor and measuring the time it takes for the evaporator temperature to fall 7 degree
Celsius (20 degree Fahrenheit). If the compressor has been running, the evaporator is cold already
and will not be capable of falling 7 degree Celsius (20 degree Fahrenheit). If the test was run with a
cold evaporator, turn A/C off and turn the blower motor switch to high position for 3 to 5 minutes till
the evaporator is to room temperature. Then repeat the Calibration Diagnostic and Cool-down test.
If refrigerant system is performing properly and the system will not pass test. Repeat the
Calibration Diagnostic and Cool-down test to determine if the evaporator temperature FIN sensor
has developed an open or a short circuit. If the HVAC control module still passes Calibration test,
verify Cool-down test manually with a pocket thermometer. The outlet air temperature must drop at
least 7 degree Celsius (20 degree Fahrenheit) within two minutes. If the vehicle passes with the
manual thermometer, take HVAC control to level 4 (evaporator probe temperature readout) and
repeat the Cool-down test. Ensure the evaporator is at room temperature before starting test.
Check if evaporator probe will drop the temperature 7 degree Celsius (20 degree Fahrenheit) in
two minutes. If the Evaporator Probe is found to be faulty, check that the sensor is positioned in the
evaporator fins properly. If not, correct and repeat test. If OK, replace the evaporator probe.
Once the repairs are completed, repeat the Calibration Diagnostic and Cool-down test. Repeating
the test is necessary to clear the fault codes.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement
Control Assembly: Service and Repair Heater-A/C Control Lamp Replacement
HVAC Control Lamps
REMOVAL
1. Remove radio bezel and HVAC Control. 2. Remove rear cover from HVAC control. 3. Rotate
bulb socket counter clockwise one quarter turn. 4. Pull bulb socket from HVAC.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 7071
Control Assembly: Service and Repair Radio Bezel and HVAC Control Replacement
REMOVAL
1. Remove convenience bin-cup holder. 2. Insert the trim stick (special tool #C-4755) between
access cover and radio bezel, above convenience bin-cup holder.
Convenience Bin Access Cover
3. Carefully pry the access cover from the instrument panel. 4. Separate the access cover from the
vehicle. 5. Remove convenience bin-cup holder track.
Radio Bezel And HVAC Control
6. Remove the attaching screws holding bottom of the bezel to instrument panel. 7. Remove the
attaching screws holding top of the bezel to the instrument panel. 8. Remove the bezel from the
instrument panel. 9. Disconnect the wire connector from back of the rear blower switch, if
equipped.
10. Disconnect the wire connector from the back of the HVAC Control. 11. Remove the bezel.
INSTALLATION
1. Hold the radio bezel up and connect the wire connector into the back of the HVAC control. 2.
Connect the wire connector into back of the rear blower switch, if equipped. 3. Place the radio
bezel in position on the instrument panel. 4. Install screws to hold the top of radio bezel to
instrument panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 7072
5. Install screws to the hold bottom of the radio bezel to the instrument panel. 6. Install the access
cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 7073
Control Assembly: Service and Repair Rear Heater-A/C Switch Lamp Replacement
Rear Heater - A/C Switch Lamp Bulb
REMOVAL
1. Remove radio bezel HVAC Control. 2. Rotate bulb socket counter clockwise one quarter. 3. Pull
bulb socket from switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 7074
Control Assembly: Service and Repair Rear Heater-A/C Switch Replacement
Rear Heater - A/C Switch
REMOVAL
1. Remove radio bezel and HVAC Control. 2. Remove screw holding rear heater - A/C switch to
radio bezel HVAC Control. 3. Disengage hook holding bottom of switch to radio bezel HVAC
Control. 4. Remove switch from radio bezel HVAC Control.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Control Assembly, HVAC > Component Information > Service
and Repair > Heater-A/C Control Lamp Replacement > Page 7075
Control Assembly: Service and Repair Sticking HVAC Control Module Push Buttons
Sticking HVAC Control Module Push Buttons
To service HVAC control module push buttons that are sticking, spray between the buttons with
Mopar MP-50. The MP-50 is a all purpose lubricant for mechanical and electrical uses. After
spraying around the push buttons wipe any excess off the radio bezel and HVAC control module
push buttons. Operate the buttons to ensure that they are operating freely.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 7084
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 7085
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 7086
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 7087
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7093
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7094
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7095
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Case: > 23-43-97A > Sep > 97 > Evaporator Housing Water Leaks Onto The Floor > Page 7096
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly
Evaporator Case: Service and Repair Evaporator Housing Disassembly and Assembly
DISASSEMBLY
1. Place HVAC unit assembly on workbench.
Distribution Housing
2. Remove distribution housing mounting screws.
Blower Motor Cover
3. Remove blower motor cover.
Blower Motor Grommet
4. Remove blower motor wiring grommet and feed wiring through blower housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly > Page 7099
Blower Motor Screws
Blower Motor
5. Remove blower motor screws. Remove blower motor from housing.
Recirculation Door Cover
6. Remove recirculation door cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly > Page 7100
RECIRC Door
7. Remove Recirc. door.
HVAC Cover
8. Remove screws around the perimeter of the upper HVAC housing.
CAUTION: Do not damage the insulation barrier surrounding the evaporator.
Evaporator
9. Carefully pull up on evaporator and remove from housing.
10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of
the same amount (ND8 PAG) to the new
evaporator before installing.
ASSEMBLY
1. For reassembly of the evaporator housing, reverse the above procedures. 2. Perform the HVAC
control Calibration Diagnostic and Cool-down test. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly > Page 7101
Evaporator Case: Service and Repair Evaporator Housing Removal and Installation
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING, THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING.
1. Set parking brake. 2. Disconnect battery negative cable.
A/C Service Ports
3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper
module. See: Relays and Modules/Relays and Modules - Wiper and Washer Systems/Wiper
Control Module/Service and Repair 5. Pinch off rear heater lines if equipped.
Heater Hoses
6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly > Page 7102
Expansion Valve Plate
7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel
Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and
Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
9. Remove heater ducts.
10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the
tunnel.
HVAC Bolt Up
11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12
Disconnect the HVAC housing wiring harness.
13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing
inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic
and Cool-down test. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly > Page 7103
Evaporator Case: Service and Repair Rear Evaporator Removal and Installation
NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF
ALL PRESSURE.
1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3.
Remove rear A/C unit. 4. Remove blower scroll.
Evaporator Cover
5. Remove evaporator cover.
Expansion Valve
6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Case > Component Information > Service and
Repair > Evaporator Housing Disassembly and Assembly > Page 7104
Evaporator Removal
7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots. 8. Remove and discard the O-rings between the
plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to
prevent contamination.
10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx
Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil
from the removed evaporator.
INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate
(do not scratch the sealing surface). Install two screws and tighten to 11 ± 3 NM (100 ± 30
inch pounds) torque.
CAUTION: Do not damage the evaporator insulation liner during installation.
3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the
sealing surfaces with the plumbing extension tube
pilots.
4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot
tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten bolts to 23 +/- 3 N.m (200 +/- 30 inch pounds)
torque.
6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system,
and perform the performance test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Specifications
Evaporator Core: Specifications
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................... 150 ml (5.0 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core
Evaporator Core: Service and Repair Front Evaporator Core
REMOVAL
1. Set parking brake. 2. Disconnect battery negative cable.
A/C Service Ports
3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper
module. See: Relays and Modules/Relays and Modules - Wiper and Washer Systems/Wiper
Control Module/Service and Repair 5. Pinch off rear heater lines if equipped.
Heater Hoses
6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7110
Expansion Valve Plate
7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel
Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and
Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
9. Remove heater ducts.
10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the
tunnel.
HVAC Bolt Up
11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12
Disconnect the HVAC housing wiring harness.
13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
Evaporator Core Removal
1. Place HVAC unit assembly on workbench.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7111
Distribution Housing
2. Remove distribution housing mounting screws.
Blower Motor Cover
3. Remove blower motor cover.
Blower Motor Grommet
4. Remove blower motor wiring grommet and feed wiring through blower housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7112
Blower Motor Screws
Blower Motor
5. Remove blower motor screws. Remove blower motor from housing.
Recirculation Door Cover
6. Remove recirculation door cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7113
Recirculation Door
7. Remove recirculation door.
HVAC Cover
8. Remove screws around the perimeter of the upper HVAC housing.
CAUTION: Do not damage the insulation barrier surrounding the evaporator.
Evaporator
9. Carefully pull up on evaporator and remove from housing.
10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of
the same amount (ND8 PAG) to the new
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7114
evaporator before installing.
Note: For reassembly of the evaporator housing, reverse the above procedures.
- Perform the HVAC control Calibration Diagnostic and Cool-down test. See: Testing and
Inspection
INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing
inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic
and Cool-down test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7115
Evaporator Core: Service and Repair Rear Evaporator Core
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF
ALL PRESSURE.
1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3.
Remove rear A/C unit. 4. Remove blower scroll.
Evaporator Cover
5. Remove evaporator cover.
Expansion Valve
6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Core > Component Information > Service and
Repair > Front Evaporator Core > Page 7116
Evaporator Removal
7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots. 8. Remove and discard the 0-rings between the
plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to
prevent contamination.
10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx
Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil
from the removed evaporator.
INSTALLATION
1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate (do not scratch
the sealing surface). Install two screws and tighten to 11 ± 3 Nm (100 ± 30
inch pounds) torque.
CAUTION: Do not damage the evaporator insulation liner during installation.
3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the
sealing surfaces with the plumbing extension tube
pilots.
4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot
tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten bolts to 23 ± 3 Nm (200 ± 30 inch pounds)
torque.
6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system,
and perform the performance test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water
Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water
Leaks Onto The Floor > Page 7125
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water
Leaks Onto The Floor > Page 7126
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water
Leaks Onto The Floor > Page 7127
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Customer Interest for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator Housing - Water
Leaks Onto The Floor > Page 7128
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator
Housing - Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator
Housing - Water Leaks Onto The Floor > Page 7134
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator
Housing - Water Leaks Onto The Floor > Page 7135
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator
Housing - Water Leaks Onto The Floor > Page 7136
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Evaporator Drain Tube: > 23-43-97A > Sep > 97 > Evaporator
Housing - Water Leaks Onto The Floor > Page 7137
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Drain Tube > Component Information > Technical
Service Bulletins > Page 7138
Evaporator Drain Tube: Description and Operation
SYSTEM OPERATION
Condensate Drain Condensation from the evaporator housing is drained through the dash panel
and on to the ground. This drain must be kept open to prevent water from collecting in the bottom
of the housing.
If the drain is blocked condensate cannot drain, causing water to back up and spill into the
passenger compartment. It is normal to see condensate drainage below the vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection
Evaporator Temperature Sensor / Switch: Testing and Inspection
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
- Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one's digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cool-down test is exited.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Evaporator Temperature Sensor / Switch > Component
Information > Testing and Inspection > Page 7142
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
- For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Testing and
Inspection
Expansion Valve: Testing and Inspection
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
Tests
NOTE: Expansion valve tests should be performed after compressor tests.
Review Safety Precautions and Warnings. The work area and vehicle temperature must be 21
degree Fahrenheit to 27 degree Celsius (70 degree Fahrenheit to 85 degree Fahrenheit). To test
the expansion valve:
NOTE: Liquid CO2 is required to test the expansion valve. It is available from most welding supply
facilities. CO2 is also available from companies which service and sell fire extinguishers.
1. Connect a charging station or manifold gauge set to the refrigerant system service ports. Verify
the refrigerant charge level. 2. Close all doors, windows and vents to the passenger compartment.
3. Set heater A/C control to A/C, full heat, FLOOR, and high blower. 4. Start the engine and allow
to idle (1000 rpm). After the engine has reached running temperature, allow the passenger
compartment to heat up.
This will create the need for maximum refrigerant flow into the evaporator.
5. If the refrigerant charge is sufficient, discharge (high pressure) gauge should read 965 to 1655
kPa (140 to 240 psi). Suction (low pressure)
gauge should read 140 kPa to 207 kPa (20 psi to 30 psi). If system cannot achieve proper pressure
readings, replace the expansion valve. If pressure is correct, proceed with test.
WARNING: PROTECT SKIN AND EVES FROM CONTACTING CO2 PERSONAL INJURY CAN
RESULT.
6. If suction side low pressure is within specified range, freeze the expansion valve control head for
30 seconds. Use a super cold substance
(liquid CO2). Do not spray R-134a or R-12 Refrigerant on the expansion valve for this test. Suction
side low pressure should drop by 10 psi. If not, replace expansion valve.
7. Allow expansion valve to thaw. The low pressure gauge reading should stabilize at 140 kPa to
240 kPa (20 psi to 30 psi). If not, replace
expansion valve.
8. When expansion valve test is complete, test A/C overall performance. Remove all test
equipment before returning vehicle to use.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation
Expansion Valve: Service and Repair Expansion Valve Removal and Installation
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3.
Remove the accessory drive belt. 4. Remove upper generator bracket. 5. Disconnect generator
field wire connector. 6. Push generator forward. 7. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
8. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
9. Remove the stud from the expansion valve.
10. Carefully pull the refrigerant line sealing plate assembly from expansion valve towards the front
of the vehicle. Use care not to scratch the
expansion valve sealing surfaces with pilot tubes.
11. Cover the openings to prevent contamination. 12. Remove two screws securing the expansion
valve to the evaporator sealing plate.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation > Page 7148
Expansion Valve Removal
13. Carefully remove expansion valve. 14. Remove the old O-rings.
INSTALLATION 1. Ensure old O-rings are removed. Install new O-rings on the refrigerant lines and
evaporator sealing plate. 2. Hand-start the stud into the expansion valve and torque to 7 - 11 N.m
(64 - 96 in. lbs.). 3. Carefully install the expansion valve to the sealing plate. Install the two screws
and tighten 8 to 14 N.m (70 to 130 in. lbs.) torque. 4. Carefully install the refrigerant lines and
sealing plate to the expansion valve. Install the nut and tighten 20 to 26 N.m (170 to 230 in. lbs.)
torque. 5. Install the ground wire at dash panel. 6. Pull generator back into the proper position for
bracket mounting. 7. Install generator field wire connector. 8. Install the upper generator bracket. 9.
Install accessory drive belt.
10. Evacuate and recharge system. 11. After expansion valve is installed, the system is charged,
and leaks have checked repeat the A/C performance check.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation > Page 7149
Expansion Valve: Service and Repair Evaporator Core and Expansion Valve Replacement
NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: THE REFRIGERANT SYSTEM MUST BE EMPTY BEFORE PERFORMING THE
FOLLOWING OPERATION. THE ENGINE COOLING SYSTEM MUST ALSO BE RELIEVED OF
ALL PRESSURE.
1. Remove right quarter trim panel and D-pillar trim. 2. Remove fan A/C distribution duct. 3.
Remove rear A/C unit. 4. Remove blower scroll.
Evaporator Cover
5. Remove evaporator cover.
Expansion Valve
6. Remove the nut that mounts the refrigerant plumbing block to the expansion valve.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Expansion Valve > Component Information > Service and
Repair > Expansion Valve Removal and Installation > Page 7150
Evaporator Removal
7. Carefully pull the evaporator and expansion valve straight out of unit. Do not scratch the sealing
surfaces with the plumbing extension tube pilots. 8. Remove and discard the O-rings between the
plumbing extension and the expansion valve. 9. Cover the plumbing extension sealing surface to
prevent contamination.
10. Bring evaporator and expansion valve to a clean work space. 11. Remove two 1/4-20 Torx
Head screws. 12. Remove expansion valve. 13. Measure and record the amount of residual oil
from the removed evaporator.
INSTALLATION 1. Replace the O-rings. 2. Hold expansion valve against evaporator sealing plate
(do not scratch the sealing surface). Install two screws and tighten to 11 +/- 3 N.m (100 +/30 inch pounds) torque.
CAUTION: Do not damage the evaporator insulation liner during installation.
3. Carefully install the evaporator and expansion valve straight into the unit. Do not scratch the
sealing surfaces with the plumbing extension tube
pilots.
4. Determine the amount of old refrigerant oil drained from the evaporator. Add this amount (of
clean refrigerant oil) back into the system. 5. Carefully align the expansion valve onto the pilot
tubes of the plumbing extension (do not scratch the sealing surface). Install the bolt through the
plumbing plate into the unit sealing plate. Tighten bolts to 23 +/- 3 N.m (200 +/- 30 inch pounds)
torque.
6. Install evaporator cover and blower scroll. 7. Install quarter trim panel, evacuate/charge system,
and perform the performance test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core
Heater Core: Service and Repair Front Heater Core
REMOVAL
1. Drain coolant system. See: Engine, Cooling and Exhaust/Cooling System/Service and Repair 2.
Remove left side lower column cover. Refer to: "Body and Frame : Interior Trim : Dashboard /
Instrument Panel : Service and Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
3. Remove steering column assembly. See: Steering and Suspension/Steering/Steering
Column/Service and Repair
ABS Module
4. Remove ABS module, bracket and wiring. See: Brakes and Traction Control/Antilock Brakes /
Traction Control Systems/Electronic Brake
Control Module/Service and Repair
Interconnect And Bracket
5. Remove I/P to body harness interconnect and bracket.
Lower Silencer Boot
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 7155
6. Remove lower silencer boot at base of steering shaft. 7. Pinch off heater lines under the hood.
Heater Core Plate And Tubes
8. Remove heater core cover. Insert a small amount of towels under the heater core tubes.
Remove heater core plate and tubes.
Depress Clips
9. Depress heater core retaining clips.
Accelerator Pedal
10. Pull up on accelerator pedal and slide heater core past.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 7156
Brake Pedal
11. Depress brake pedal and remove heater core from HVAC housing.
INSTALLATION
- For installation, reverse the above procedures. Install screws to retain heater core in housing.
Replace heater core tube inlet O-rings. Tighten heater core tube retaining plate to 3 ± 1 N.m (27 ±
9 in. lbs.) torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Core > Component Information > Service and Repair >
Front Heater Core > Page 7157
Heater Core: Service and Repair Rear Heater Core
REMOVAL
1. Remove the lower right quarter trim panel.
Heater Core Lines
2. Isolate and disconnect lines from heater core. 3. Remove heater core retaining screws. 4.
Carefully pull the heater core and tubes up and straight out of the unit.
INSTALLATION
Filling Heater Core
- For installation, reverse the above procedures. Prefill the heater core. Test for leaks and overall
performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be used: Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor on HIGH
- Discharge air temperature, measured at the dual register located on the C-pillar base, is between
57 degree Celsius to 62 degree Celsius (135 degree and 145 degree Fahrenheit).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Locations
Heater Hose: Locations
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Locations > Page
7161
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hoses
Heater Hose: Service and Repair Heater Hoses
REMOVAL
NOTE: Review Safety Precautions and Warnings before proceeding with this operation.
1. Drain engine cooling system.
Upper Heater Hose
Lower Heater Hose
2. Loosen clamps at each end of heater hose to be removed.
CAUTION: When removing hoses from heater core in let or outlet nipples, do not use excessive
force. Heater core may become damaged and leak engine coolant.
3. Carefully rotate hose back and forth while tugging slightly away from connector nipple. If the
hose will not come off, slice the hose at the
connector nipple and peel off heater hose. This method will require heater hose replacement.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hoses > Page 7164
Heater Hose: Service and Repair Underbody Plumbing
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Heater Hose > Component Information > Service and Repair >
Heater Hoses > Page 7165
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
For more information, refer to Heater core/ Service and Repair. See: Heater Core/Service and
Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation
High Pressure Safety Valve HVAC: Description and Operation
SYSTEM OPERATION
A/C Pressure Transducer
A/C Pressure Transducer
The A/C Pressure Transducer monitors the refrigerant gas pressure on the high side of the system.
The transducer is located on the liquid line. The pressure transducer turns off the voltage to the
compressor clutch coil when refrigerant gas pressure drops to levels that could damage the
compressor. The transducer also is used to adjust condenser fan speeds and will turn off
compressor at high refrigerant pressures. The pressure transducer is a sealed factory calibrated
unit. It must be replaced if defective. 0-ring replacement is required whenever the pressure
transducer is serviced. Be sure to use the 0-ring specified for the transducer.
Compressor High-Pressure Relief Valve
The High Pressure Relief Valve prevents damage to the air conditioning system if excessive
pressure develops. Excessive pressure can be caused by condenser air flow blockage, refrigerant
overcharge, or air and moisture in the system.
The high pressure relief valve vents only a small amount of refrigerant necessary to reduce system
pressure and then reseats itself. The majority of the refrigerant is conserved in the system. The
valve is calibrated to vent at a pressure of 3450 to 4140 kPa (500 to 600 psi). If a valve has vented
a small amount of refrigerant, it does not necessarily mean the valve is defective.
The High Pressure Relief Valve is located on the compressor manifold at the discharge passage.
NOTE: Special effort must be used to keep all R-134a system components moisture free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > Page 7169
High Pressure Safety Valve HVAC: Testing and Inspection
The work area temperature must not be below 10 degree Celsius (50 degree Fahrenheit) to test
the compressor clutch circuit. Before starting to test the transducer ensure that the wire connector
is clean of corrosion and connected properly.
1. With gear selector in park or neutral and park brake set, start engine and allow to idle. 2. Install
scan tool (DRB):
- Go to main menu
- Select stand alone scan tool (DRB)
- Select refer to the proper year diagnostics
- Select climate control
- Select sensor display
- Select A/C high side volts
For A/C system to operate a voltage between 0.451 (Low Pressure Cutout) to 4.519 (High
Pressure Cutout is required. Voltages outside this range indicate a low or high pressure condition
and will not allow the compressor to cycle.
A/C Pressure Transducer Voltage
Refer to the A/C Pressure Transducer Voltage table for the appropriate condition(s)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > High Pressure Safety Valve HVAC > Component Information >
Description and Operation > Page 7170
High Pressure Safety Valve HVAC: Service and Repair
REMOVAL
1. Disconnect the wire connector at the pressure transducer.
A/C Pressure Transducer Removal
2. Using an open end wrench, remove the transducer from the liquid line.
INSTALLATION
1. Replace transducer O-ring. 2. For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > A/C Suction/Discharge Line - Service
Hose/Line HVAC: Technical Service Bulletins A/C Suction/Discharge Line - Service
NUMBER: 24-14-99
GROUP: Heating & A/C
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 24-11-98 REV. A, DATED
JULY. 24, 1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-99003). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS.
SUBJECT: A/C Suction And/Or Discharge Line Service
MODELS:
1996 - **2000** (NS) Town & Country/Caravan/Voyager 1996 - **2000** (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
DISCUSSION: It an A/C suction and/or discharge line requires replacement due to cracking at or
near the compressor, inspect the three (3) A/C compressor mounting bolts and be sure they are
torqued to 40 ft. lbs. (54 Nm).
The root cause of A/C suction and/or discharge line cracking at or near the compressor may be
related to the compressor being improperly secured to the engine. Excessive vibration may result if
the compressor attaching bolts are not properly torqued. This vibration will eventually crack the
aluminum tubing of the A/C lines and/or compressor mounting ears.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Page 7175
Hose/Line HVAC: Locations
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Page 7176
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Page 7177
Hose/Line HVAC: Description and Operation
SYSTEM OPERATION
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Rear Heater Hose Connection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Technical
Service Bulletins > Page 7178
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is dean of any contaminations that can get in to the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement
Hose/Line HVAC: Service and Repair A/C Discharge Hose/Line Replacement
REMOVAL
1. Recover A/C system refrigerant.
Compressor Discharge Line
2. Remove discharge line mounting nut at compressor.
Condenser Discharge Line
3. Remove discharge line at the top fitting on the condenser.
INSTALLATION
1. For installation, reverse the above procedures. Replace all O-rings. Torque discharge line at
condenser bolt to 180 in. lbs. +/- 10. 2. Evacuate and recharge A/C system. 3. Perform the HVAC
Control Calibration Diagnostic and Cool-down test.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 7181
Hose/Line HVAC: Service and Repair A/C Liquid Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove liquid line from expansion valve. 9.
Cover the openings to prevent contamination.
10. Disconnect wire connector at pressure transducer. 11. Remove liquid line mounting bracket at
right frame rail. 12. Using access slot between radiator crossmember and grille, loosen liquid line
mounting plate at filter-drier. Remove liquid line from filter-drier. It
may be necessary to bend liquid line in half to remove line. The replacement line is a two-piece
assembly
13. Remove the old O-rings.
INSTALLATION
- For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 7182
Hose/Line HVAC: Service and Repair A/C Suction Hose/Line Replacement
REMOVAL
1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3. Remove the
accessory drive belt. 4. Remove upper generator bracket. 5. Remove ground wire at dash panel.
A/C Refrigerant Line Plate
6. Remove the nut retaining the refrigerant line sealing plate to the expansion valve.
Expansion Valve Stud And Mounting Screws
7. Remove the stud from the expansion valve. 8. Remove suction line from expansion valve.
Suction Line At Compressor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 7183
9. Remove suction line mounting nut at compressor.
10. Remove suction line mounting bracket. 11. Remove suction line.
INSTALLATION
- For installation, reverse the above procedures.
- Install the stud to the evaporator sealing plate and tighten 7 to 11 N.m (64 to 96 in. lbs.) torque.
- Install new O-rings.
- Install two-piece line in place of original part.
- Assemble line halves after it is installed on vehicle.
- Evacuate and recharge A/C system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 7184
Hose/Line HVAC: Service and Repair Refrigerant Line Replacement
Rear Air Conditioning Lines
Rear Heater And A/C Lines
Front Lines Connected To Rear Lines
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Hose/Line HVAC > Component Information > Service and
Repair > A/C Discharge Hose/Line Replacement > Page 7185
Rear Heater Hose Connection
Rear Heater Hose Quick Connects
Rear A/C Block Connection
The rear heater and A/C lines are all serviced as individual pieces. When disconnecting any line or
block ensure that the area around it is clean of any contaminations that can get in to the system.
For more information, refer to Housing Assembly HVAC/ Service and Repair. See: Housing
Assembly HVAC/Service and Repair
Rear Heater A/C Air Outlets
REMOVAL
- Separate barrel from bezel by pulling outward.
INSTALLATION
- For installation, push the outlet firmly into the opening until it locks into place.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly
Housing Assembly HVAC: Service and Repair Evaporator Housing Disassembly and Assembly
DISASSEMBLY
1. Place HVAC unit assembly on workbench.
Distribution Housing
2. Remove distribution housing mounting screws.
Blower Motor Cover
3. Remove blower motor cover.
Blower Motor Grommet
4. Remove blower motor wiring grommet and feed wiring through blower housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7190
Blower Motor Screws
Blower Motor
5. Remove blower motor screws. Remove blower motor from housing.
Recirculation Door Cover
6. Remove recirculation door cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7191
Recirculation Door
7. Remove Recirc door.
HVAC Cover
8. Remove screws around the pen meter of the upper HVAC housing.
CAUTION: Do not damage the insulation barrier surrounding the evaporator.
Evaporator
9. Carefully pull up on evaporator and remove from housing.
10. If replacing evaporator, drain and measure amount of oil from old evaporator and add new oil of
the same amount (ND8 PAG) to the new
evaporator before installing. Use SP 10 PAG oil for 2.5L diesel and 2.0L gasoline engine vehicles.
ASSEMBLY
1. For reassembly of the evaporator housing, reverse the above procedures. 2. Perform the HVAC
control Calibration Diagnostic and Cool-down test. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7192
Housing Assembly HVAC: Service and Repair Distribution Housing Disassembly and Assembly
DISASSEMBLY
Distribution Housing
1. Place distribution housing on workbench.
Heater Core Cover
2. Remove heater core cover.
Heater Core Tube Plate
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7193
Plate Removal
3. Remove heater core tube plate.
Heater Core Tube Removal
4. Remove heater core tubes. 5. Depress heater core retaining clips at housing. When reinstalling
core use screws to fasten the heater core to the housing. 6. Slide heater core out of the housing.
Driver's Zone Actuator
7. Remove driver's zone actuator from distribution housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7194
Passenger Zone Actuator
8. Remove passenger zone actuator from distribution housing.
Distribution Housing
Blend Air Door Drive Gear
9. Using a long thin flat blade tool, insert tool through blend-air opening on top of distribution
housing. Depress clip retaining the driver's blend-air
door drive gear. Pull out on gear and remove from the housing.
10. Remove mode door motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7195
Panel Door Gear
11. Remove Panel door actuator gear.
Defrost Door Gear
12. Remove defrost door actuator gear.
Cam Wheel
13. Remove cam wheel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7196
Heat Door Gear
14. Remove heat door actuator gear.
Distribution Housing
15. Remove distribution housing lower cover screws.
Distribution Housing Half Screws
16. Remove distribution housing half screws.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7197
Front Cover
View Of Zone Control Doors
17. Remove distribution housing front cove. 18. Remove weather-strip at fresh-air vent.
Distribution Housing Halves
19. Separate housing halves.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7198
Defrost Door
20. Pull up on separator plate and remove defrost door.
Panel Door
21. Remove upper half Panel door.
Floor Door
22. Remove upper half of Floor door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7199
Blend Air Door
23. Remove upper half of the blend-air door (slide off of shaft).
Separator Plate
24. Remove separator plate from distribution housing.
Lower Blend Air Door
25. Remove lower half of the blend-air door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7200
Lower Panel Door
26. Remove lower half of the Panel door.
Lower Floor Door
27. Remove lower half of the Floor door.
ASSEMBLY
- For reassembly of the distribution housing, reverse the above procedures.
- To reassemble the distribution housing actuator gears an assembly procedure of the gears and
cam is necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7201
Housing Assembly HVAC: Service and Repair Heater - A/C Housing Removal and Installation
REMOVAL
WARNING: IF EQUIPPED WITH AIR CONDITIONING, THE REFRIGERATION SYSTEM MUST
BE COMPLETELY EMPTY BEFORE PROCEEDING.
1. Set parking brake. 2. Disconnect battery negative cable.
A/C Service Ports
3. Using a refrigerant recovery machine, remove refrigerant from the A/C system. 4. Remove Wiper
module. See: Relays and Modules/Relays and Modules - Wiper and Washer Systems/Wiper
Control Module/Service and Repair 5. Pinch off rear heater lines if equipped.
Heater Hoses
6. Drain engine coolant. Remove heater hoses at the heater core. Plug coolant lines.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7202
Expansion Valve Plate
7. Remove suction and liquid lines at the expansion valve. 8. Remove the Instrument Panel
Assembly. Refer to: "Body and Frame : Interior Trim : Dashboard / Instrument Panel : Service and
Repair".
See: Body and Frame/Interior Moulding / Trim/Dashboard / Instrument Panel/Service and Repair
9. Remove heater ducts.
10. Disconnect the two upper mounts from the upper reinforcement and the lower mount from the
tunnel.
HVAC Bolt Up
11. Remove the (3) nuts (in the engine compartment) securing the unit to the dash panel. 12
Disconnect the HVAC housing wiring harness.
13 Pull the entire unit rearward until the studs on the unit clear the dash panel. Drop the unit down.
Pull it rearward to remove it from vehicle.
INSTALLATION
1. For installation of the assembly, reverse the above procedures. Install new O-rings on plumbing
inlets 2. Evacuate and recharge the A/C system. 3. Perform HVAC control Calibration Diagnostic
and Cool-down test. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7203
Housing Assembly HVAC: Service and Repair Rear Heater-A/C Housing Removal and Installation
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST
BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING
SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE.
1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit. 2. Hoist vehicle.
A/C Lines
3. Remove A/C lines at lower floor pan flange.
A/C Mounting
4. Remove (3) A/C unit floor mounting nuts. 5. Lower vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7204
Quarter Trim Panel
6. Remove right quarter trim panel and D-pillar trim.
Lower Heater Duct
7. Remove screws securing air distribution duct to the rear wheel housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7205
Heater Core Lines
8. Pinch off heater lines at heater core hookup.
Heater Hoses
9. Remove heater hoses at heater core.
Trim Panel Mounting Bracket
10. Remove quarter trim panel mounting bracket. 11. Remove blower motor wiring harness
connector.
Upper Duct Trim
12. Remove rear upper duct trim screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7206
Mounting Bolts
13. Remove (2) Heater-A/C housing mounting bolts.
A/C Unit Replacement
14. Pull up on upper A/C duct. Tilt A/C unit outward. 15. Lift the unit enough to clear floor pan.
Remove unit from the vehicle.
INSTALLATION
Filling Heater Core
- For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate
and charge the refrigerant system. Fill the heater core. Test for leaks and overall performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7207
used: Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor ON HIGH,
- Discharge air temperature, measured at the dual register located on the C-pillar base, is between
135 degree and 145 degree Fahrenheit.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7208
Housing Assembly HVAC: Service and Repair Rear Heater-A/C Unit Replacement and Service
NOTE: Special effort must be used to keep all R-134a system components moisture-free. Moisture
in the oil is very difficult to remove and will cause a reliability problem with the compressor.
REMOVAL
WARNING: ON VEHICLES EQUIPPED WITH REAR A/C, THE REFRIGERANT SYSTEM MUST
BE EMPTIED BEFORE PERFORMING THE FOLLOWING OPERATION. THE ENGINE COOLING
SYSTEM MUST ALSO BE RELIEVED OF ALL PRESSURE.
1. Using a refrigerant recovery machine, remove refrigerant from the A/C system. Disconnect A/C
plumbing from rear heater A/C unit. 2. Hoist vehicle.
A/C Lines
3. Remove A/C lines at lower floor pan flange.
A/C Mounting
4. Remove (3) A/C unit floor mounting nuts. 5. Lower vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7209
Quarter Trim Panel
6. Remove right quarter trim panel and D-pillar trim.
Lower Heater Duct
7. Remove screws securing air distribution duct to the rear wheel housing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7210
Heater Core Lines
8. Pinch off heater lines at heater core hookup.
Heater Hoses
9. Remove heater hoses at heater core.
Trim Panel Mounting Bracket
10. Remove quarter trim panel mounting bracket. 11. Remove blower motor wiring harness
connector.
Upper Duct Trim
12. Remove rear upper duct trim screw.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7211
Mounting Bolts
13. Remove (2) Heater-A/C housing mounting bolts.
A/C Unit Replacement
14. Pull up on upper A/C duct. Tilt A/C unit outward. 15. Lift the unit enough to clear floor pan.
Remove unit from the vehicle.
INSTALLATION
Filling Heater Core
- For installation, reverse the above procedures. Install new O-rings at refrigerant lines. Evacuate
and charge the refrigerant system. Fill the heater core. Test for leaks and overall performance.
NOTE: If the heater core was emptied and was not prefilled, it is necessary to thermal cycle the
vehicle TWICE. The heater core is positioned higher than the radiator fill cap. Therefore the heater
core will not gravity fill to level. To thermal cycle the vehicle, it must be operated till the thermostat
opens, then turned off and allowed to cool. In order to verify that the auxiliary unit is filled
completely, the following procedure can be
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Housing Assembly HVAC > Component Information > Service
and Repair > Evaporator Housing Disassembly and Assembly > Page 7212
used: Vehicle at room temperature.
- Engine is brought up to operating temperature.
- Front unit is OFF, temperature slides are at full HEAT position.
- Engine is at idle.
- With rear blower motor ON HIGH,
- Discharge air temperature, measured at the dual register located on the C-pillar base, is between
135 degree and 145 degree Fahrenheit.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications
Receiver Dryer: Specifications
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................... 150 ml (5.0 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications >
Page 7216
Filter Drier
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Receiver Dryer > Component Information > Specifications >
Page 7217
Receiver Dryer: Service and Repair
REMOVAL
WARNING: The refrigeration system must be completely empty before proceeding with this
operation.
Filter Drier
1. Recover A/C system refrigerant. 2. Remove liquid line at filter-drier. 3. Remove the (2) bolts
holding filter-drier bracket to radiator fan module bracket. 4. Remove the lower liquid line at
condenser. 5. Remove the upper radiator crossmember. 6. Pull up on radiator and slide filter-drier
from the mounting location.
INSTALLATION
1. Before installation, replace both refrigerant line 0-rings. Then reverse the above procedures. 2.
Evacuate and recharge system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications
Refrigerant: Capacity Specifications
R134a Single Capacity ........................................................................................................................
........................................ 0.96 kg (34 oz. or 2.13 lbs)
R134a Dual Capacity ...........................................................................................................................
....................................... 1.36 kg (48 oz. or 3.00 lbs)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications >
Capacity Specifications > Page 7222
Refrigerant: Fluid Type Specifications
Hydrofluorocarbon (HFC), ...................................................................................................................
............................................... R-134a liquefied gas
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant > Component Information > Specifications > Page
7223
Refrigerant: Description and Operation
This vehicle uses a new type of refrigerant called R-134a. It is a non-toxic, non-flammable, clear
colorless liquefied gas.
R-134a refrigerant is not compatible with R-12 refrigerant in an air conditioning system. Even a
small amount of R-12 in a R-134a system could cause compressor failure, refrigerant oil to sludge
and/or poor performance. Never add any other type of refrigerant to a system designed to use
R-134a refrigerant. System failure will occur.
The high pressure service port is located on the liquid line near the strut tower. The low pressure
service port is located on the suction line near the compressor manifold.
Refrigerant Recovery/Recycling Station (Typical)
When servicing a system, it is required that an air conditioning charging recovery/recycling
machine be used. Contact an automotive service equipment supplier for proper equipment. Refer
to the operating instructions provided with the equipment for proper operation.
Manifold Gauge Set - Typical
A manifold gauge set must also be used in conjunction with the charging and/or recovery/recycling
device. Only use gauges that have not been used for R-12. The service hoses on the gauge set
should have manual (turn wheel) or automatic back flow valves at the service port connector ends.
This will prevent refrigerant R-134a from being released into the atmosphere.
R-134a refrigerant requires a special type of compressor oil. When adding oil, make sure to use the
oil that is specified on the under hood label.
Due to the different characteristics of R-134a it requires all new service procedures.
The use of R-134a will have a positive environmental impact due to it's zero ozone depletion and
low global warming impact.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications
Refrigerant Filter: Specifications
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Front A/C
- Compressor .......................................................................................................................................
................................................... 150 ml (5.0 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
Dual A/C
- Compressor .......................................................................................................................................
................................................... 220 ml (7.4 oz)
- Filter-Drier .........................................................................................................................................
.................................................... 30 ml (1.0 oz)
- Condenser .........................................................................................................................................
..................................................... 30 ml (1.0 oz)
- Evaporator .........................................................................................................................................
.................................................... 60 ml (2.0 oz)
- Rear Evaporator ................................................................................................................................
..................................................... 60 ml (2.0 oz)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Filter > Component Information > Specifications >
Page 7227
Refrigerant Filter: Service and Repair
REMOVAL
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
1. Recover A/C system refrigerant.
Filter Drier Assembly
2. Remove liquid line at filter-drier. 3. Remove the (2) bolts holding filter-drier bracket to radiator fan
module bracket. 4. Remove the lower liquid line at condenser. 5. Remove the upper radiator
crossmember. 6. Pull up on radiator and slide filter-drier from the mounting location.
INSTALLATION
1. Before installation, replace both refrigerant line O-rings. Then reverse the above procedure.
Torque filter/drier mounting bolts to 45 in. lbs. +/- 10. 2. Evacuate and recharge system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications
Refrigerant Oil: Capacity Specifications
Front A/C Compressor .........................................................................................................................
............................................................ 150 ml 5.0 oz.
Dual A/C Compressor ..........................................................................................................................
............................................................ 220 ml 7.4 oz.
Dual A/C Evaporator ............................................................................................................................
.............................................................. 60 ml 2.0 oz.
Condenser ...........................................................................................................................................
................................................................ 30 ml 1.0 oz.
Evaporator ...........................................................................................................................................
............................................................... 60 ml 2.0 oz. Filter-Drier ......................................................
................................................................................................................................................... 30 ml
1.0 oz.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Capacity Specifications > Page 7232
Refrigerant Oil: Fluid Type Specifications
Synthetic-based, Polyalkylene Glycol ..................................................................................................
.......................................................................... ND-8
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Oil > Component Information > Specifications >
Page 7233
Refrigerant Oil: Service and Repair
Refrigerant Oil Capacities
Refrigerant Oil Level Check When all air conditioning system is first assembled, all components
(except the compressor) are refrigerant oil free. After the system has been charged with R134a
refrigerant and operated, the oil in the compressor is dispersed through the lines and components.
The evaporator, condenser, and filter- drier will retain a significant amount of oil, refer to the
Refrigerant Oil Capacities chart. When a component is replaced, the specified amount of
refrigerant oil must be added. When the compressor is replaced, the amount of oil that is retained
in the rest of the system must be drained from the replacement compressor. When a line or
component has ruptured and oil has escaped, the compressor should be removed and drained.
The filter-drier must be replaced along with the ruptured part. The oil capacity of the system, minus
the amount of oil still in the remaining components, can be measured and poured into the suction
port of the compressor.
Example: On a dual system the evaporator retains 60 ml (2 oz). The condenser retains 30 ml (1 oz)
of oil, and system capacity may be 220 ml (7.40 oz) of oil. 220 ml minus 90 ml = 130 ml (4.40 oz).
CAUTION: The refrigerant oil used in a R-134a A/C system is unique. Use only oils which were
designed to work with R-134a refrigerant. The oil designated for this vehicle is ND8 PAG
(polyalkalene glycol).
Servicing Refrigerant Oil Level 1. Using a refrigerant recovery machine, remove refrigerant from
the A/C system. 2. Remove refrigerant lines from A/C compressor. 3. Remove compressor from
vehicle. 4. From suction port on top of compressor, drain refrigerant oil from compressor. 5. Add
system capacity minus the capacity of components that have not been replaced through suction
port on compressor. Refer to the
Refrigerant Oil Capacity Chart.
6. Install compressor, connect refrigerant lines, evacuate, and charge refrigerant system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
Refrigerant Pressure Sensor / Switch: Technical Service Bulletins Emissions, A/C, Cruise Control Manual Revisions
NUMBER: 26-03-98E
GROUP: Miscellaneous
DATE: March, 1998
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1998 2.4L/2.5L/3.0L/3.3L/3.8L - NS Powertrain Diagnostic Manual - Publication Number
81-699-97028
DESCRIPTION OF CHANGES
Revision to the Speed Control Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7238
76
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7239
78
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7240
80
Revision to the EGR System Failure Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7241
235
Revision to the A/C Pressure Sensor Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7242
292
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions > Page 7243
296
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Page 7244
A/C Pressure Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Refrigerant Pressure Sensor / Switch, HVAC > Component
Information > Technical Service Bulletins > Page 7245
A/C Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Locations > Front Blower Motor Relay
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Locations > Front Blower Motor Relay > Page 7251
Blower Motor Relay: Locations Rear Blower Relay
Rear Blower Motor Relay
This vehicle doesn't have a rear blower motor relay. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Description and Operation > Front Blower Motor Relay
Blower Motor Relay: Description and Operation Front Blower Motor Relay
Circuit Operation
Power for the blower motor is supplied on circuit C71. This circuit is HOT when the contacts in the
HVAC blower relay are CLOSED. Power for the contact side of the relay is supplied on circuit C1.
The C1 circuit is HOT at all times, and protected by a 40 amp fuse located in cavity 7 of the Power
Distribution Center (PDC).
The coil side of the relay is energized when the ignition switch is in the RUN position only. Power
for the coil side of the relay is supplied on circuit F20. This circuit connects from the fuse to the
relay
Circuit A2 connects from the fuse 8, a 10 amp, in the junction block and supplies power for circuit
A22.
Ground for the coil side of the relay is supplied on circuit Z1. This ground terminates at the left cowl
panel.
Ground for the blower motor is controlled through the blower motor resistor and the blower motor
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Blower Motor Relay >
Component Information > Description and Operation > Front Blower Motor Relay > Page 7254
Blower Motor Relay: Description and Operation Rear Blower Relay
Circuit Operation
Power for the rear blower motor is supplied on circuit C40. This circuit is protected by a 20 amp
fuse located in cavity 11 of the junction block. At LOW and MEDIUM speeds, ground for the rear
blower motor passes through the temperature sensor and one or more resistors, depending on
speed selection.
Two switches operate the rear blower motor by supplying ground; the front control switch and the
rear control switch. The front control switch must be in the ON position for the rear control switch to
operate the rear blower motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Component Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Relays and Modules - HVAC > Compressor Clutch Relay >
Component Information > Locations > Component Locations > Page 7259
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Air Conditioning Switch >
Component Information > Description and Operation
Air Conditioning Switch: Description and Operation
SYSTEM OPERATION
HVAC Mounted Switch
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Ambient Temperature Sensor
/ Switch HVAC > Component Information > Service and Repair
Ambient Temperature Sensor / Switch HVAC: Service and Repair
REMOVAL
1. Raise and support vehicle on safety stands. 2. From behind front bumper fascia, remove screw
holding sensor to radiator closure panel. 3. Remove sensor from vehicle.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Blower Motor Switch >
Component Information > Description and Operation
Blower Motor Switch: Description and Operation
SYSTEM OPERATION
The rear blower speed switch controls the rear blower with the choice of low and high speeds.
When the switch is on it allows the blower speed switch located on the rear headliner to control
rear blower speed. This switch will override the rear headliner blower switch. For operation
instructions refer to the Owner's Manual. The rear blower speed switch is serviced separately from
the A/C control module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection
Evaporator Temperature Sensor / Switch: Testing and Inspection
The evaporator probe can be tested by using the INTERMITTENT LED to display the actual
temperature the sensor is reading. The HVAC control module can only display temperatures from 1
to 99 degrees. To read the temperature, perform the following:
- Set Blower motor to any speed other than OFF
- Set A/C to ON, if A/C Clutch does not engage make sure Fail Codes 5 and 6 are cleared.To clear
the error code 5 and 6 the evaporator probe and/or the wiring repair needs to be completed. Then,
press and hold the intermittent wipe button for 5 seconds.
- Run Diagnostics (Depress REAR WIPER and REAR WASH)
- When Diagnostics is complete, Cycle to Level 4.
- Display Sequence is as follows:
- REAR WIPER LED will display the Level
- INTERMITTENT LED will display ten's digit
- Short Pause
- INTERMITTENT LED will display the one's digit.
The HVAC control module will continue to cycle the Level and then Temperature until the level is
changed or Calibration Diagnostics and Cool-down test is exited.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Evaporator Temperature
Sensor / Switch > Component Information > Testing and Inspection > Page 7273
Evaporator Temperature Sensor / Switch: Service and Repair
REMOVAL
1. Remove the glove box.
Evaporator Probe Connector
2. Disconnect the evaporator probe connector.
Evaporator Probe Grommet
3. Using a flat blade pry tool, pry the evaporator probe grommet from the HVAC housing.
Evaporator Probe
4. Remove evaporator probe from evaporator.
INSTALLATION
- For installation, reverse the above procedures. Three holes are provided in evaporator for probe
location. When reinstalling probe, use a different hole than original one. If a new evaporator is
installed, insert the probe in the uppermost hole provided.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
Refrigerant Pressure Sensor / Switch: Technical Service Bulletins Emissions, A/C, Cruise Control Manual Revisions
NUMBER: 26-03-98E
GROUP: Miscellaneous
DATE: March, 1998
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1998 2.4L/2.5L/3.0L/3.3L/3.8L - NS Powertrain Diagnostic Manual - Publication Number
81-699-97028
DESCRIPTION OF CHANGES
Revision to the Speed Control Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 7278
76
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 7279
78
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 7280
80
Revision to the EGR System Failure Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 7281
235
Revision to the A/C Pressure Sensor Test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 7282
292
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Emissions, A/C, Cruise Control - Manual Revisions
> Page 7283
296
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Page 7284
A/C Pressure Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Sensors and Switches - HVAC > Refrigerant Pressure Sensor /
Switch, HVAC > Component Information > Technical Service Bulletins > Page 7285
A/C Pressure Sensor Connector
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description
and Operation
Service Port HVAC: Description and Operation
SYSTEM OPERATION
Valve Service Ports
The A/C service port valve cores are located within the A/C lines. The High Side (Discharge) valve
service port is located on the liquid line near the right frame rail. The Low Side (Suction) valve
service port is located on the suction line near the compressor.
The High Side service port is a two piece port and is serviceable. The Low Side service port is not
serviceable, the suction line would have to be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Heating and Air Conditioning > Service Port HVAC > Component Information > Description
and Operation > Page 7289
Service Port HVAC: Service and Repair
WARNING: THE REFRIGERATION SYSTEM MUST BE COMPLETELY EMPTY BEFORE
PROCEEDING WITH THIS OPERATION.
The High Side service port is serviceable, the Low Side is not serviceable.
REMOVAL 1. Disconnect the battery negative cable. 2. Recover A/C system refrigerant. 3.
Unscrew the High Side service port from the liquid line. 4. Remove O-ring
INSTALLATION For installation, reverse the above procedures. Install new O-ring.
- Evacuate and recharge A/C system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming > Page 7297
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Airbag/Clock Spring - Service
Air Bag: Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Airbag/Clock Spring - Service > Page 7302
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Page 7303
Air Bag: Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Technical Service
Bulletins > Page 7304
Air Bag: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Airbag Module Storage & Handling
Air Bag: Service and Repair Airbag Module Storage & Handling
DEPLOYED MODULE
The vehicle interior may contain a very small amount of sodium hydroxide powder, a by-product of
airbag deployment. Sodium hydroxide powder can irritate the skin, eyes, nose and throat. Wear
safety glasses, rubber gloves, and long sleeved clothing when cleaning any of the powder residue
from the vehicle.
If you find that the cleanup is irritating your skin, run cool water over the affected area. Also, if you
experience nasal or throat irritation, exit the vehicle for fresh air until the irritation ceases. If irritation
continues, see a physician.
UNDEPLOYED
The airbag modules must be stored in its original special container until used for service. At no time
should a source of electricity be permitted near the inflator on the back of an airbag module. When
carrying or handling an undeployed airbag module, the trim side of the airbag should be pointing
away from the body to minimize possibility of injury if accidental deployment occurs. Do not place
undeployed airbag face down on a solid surface, the airbag will propel into the air if accidentally
deployment occurs.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Airbag Module Storage & Handling > Page 7307
Air Bag: Service and Repair Driver Side Airbag Module Replacement
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIR-BAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIR BAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
DEPLOYED MODULE The Driver Airbag Module and Driver Airbag Cover/Horn Pad are serviced
separately from each other.
REMOVAL 1. Disconnect battery negative cable. Allow at least two minutes for the reserve
capacitor in the ACM to discharge. 2. Clean powder residue from interior of vehicle, refer to
Cleanup Procedure.
Airbag/Horn Switch
3. Remove three screws attaching Driver Airbag Module to steering wheel. 4. Remove airbag
module from steering wheel. 5. Disconnect wire connectors from Airbag Module, horn switch, and
speed control switches.
6. Adjust the steering wheel so that the tires are in a straight ahead position. Remove steering
wheel. 7. Disconnect the 2-way and 4-way connectors between the clockspring and the instrument
panel wiring harness. 8. Remove upper and lower steering column shrouds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Airbag Module Storage & Handling > Page 7308
Clockspring Locking Tabs
9. Remove clockspring from the housing assembly by depressing the 2 tabs on the clockspring.
10. Remove screws holding speed control switches to airbag cover and remove, if equipped.
INSTALLATION For installation, reverse the above procedures. Do not connect battery negative
cable.
UNDEPLOYED MODULE
REMOVAL 1. Disconnect battery negative cable. Allow at least two minutes for the reserve
capacitor in the Airbag Control Module (ACM) to discharge. 2. Remove screws attaching
airbag/horn switch to steering wheel. 3. Remove Driver Airbag Module from steering wheel. 4.
Disconnect wire connectors from airbag module, horn switch, and speed control switches, if
equipped. 5. Remove screws holding vehicle speed control switches to airbag cover and remove.
INSTALLATION For installation, reverse the above procedures and do not connect battery negative
cable. Do not connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag > Component Information > Service and
Repair > Airbag Module Storage & Handling > Page 7309
Air Bag: Service and Repair Passenger Side Airbag Module Replacement
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIR-BAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
DEPLOYED MODULE
REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the
reserve capacitor in the Airbag Control Module to discharge. 2. Clean powder residue from interior
of vehicle, refer to Cleanup Procedure. 3. Remove instrument panel. 4. Remove all reusable
components from the upper instrument panel.
INSTALLATION Transfer all reusable components to the new the upper instrument panel. 1. Install
new Passenger Airbag Module into instrument panel. 2. Install airbag module attaching screws to
the instrument panel. 3. Install Instrument panel. 4. Through access holes in instrument panel
above glove box opening, install screws holding airbag to back of panel.
Airbag Upper Attachment
5. Install the bolts attaching forward airbag mount to the instrument panel. 6. Connect yellow wire
connector from passenger airbag. 7. Install the glove box. 8. Install right front instrument panel
speaker. 9. Install instrument panel top cover.
10. Do not connect battery negative cable.
UNDEPLOYED
REMOVAL 1. Disconnect battery negative cable. Allow at least two minutes for the reserve
capacitor in the ACM to discharge. 2. Remove instrument panel top cover. 3. Remove right front
instrument panel speaker. 4. Remove glove box. 5. Disconnect yellow wire connector from
passenger airbag. 6. Remove bolts attaching forward airbag mount to the instrument panel 7.
Through access holes in instrument panel above glove box opening, remove screws holding airbag
to back of panel. 8. Remove screws attaching airbag to upper instrument panel. 9. Remove airbag
from instrument panel through top of instrument panel.
INSTALLATION For installation, reverse the above procedures. Do not connect battery negative
cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7313
Air Bag Control Module: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7314
Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The
ACM monitors the system to determine the system readiness. The ACM contains on-board
diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs.
The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or
serious injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Airbag Module Locations
Driver And Passenger Airbag Modules The Driver Airbag Module is located in the center of the
steering wheel. The Passenger Airbag Module is located in the instrument panel above the glove
box. The Driver Airbag Module cover contains the horn switch, inflator device, and a fabric bag.
The airbag cover/horn switch is serviced separately from the inflator and bag components. The
Passenger Airbag Module is serviced as an assembly.
WARNING: WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION, THE
FOLLOWING MUST BE REPLACED: COMPLETE STEERING COLUMN ASSEMBLY
- LOWER STEERING COUPLER
- STEERING WHEEL
- STEERING COLUMN CLOCKSPRING
- DRIVER AIRBAG COVER/HORN SWITCH
- DRIVER AIRBAG MODULE
- PASSENGER AIRBAG MODULE
- UPPER INSTRUMENT PANEL WITH PAD.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7315
Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7316
Air Bag Control Module: Service and Repair
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the
reserve capacitor in the Airbag Control Module (ACM) to
discharge.
2. Remove forward lower console from instrument panel.
Heat Duct
3. Remove screw holding lower heat duct to instrument panel support. 4. Remove heat duct from
instrument panel.
5. Remove two bolts holding top of right support to instrument panel. 6. Remove two bolts holding
bottom of right support to floor pan. 7. Separate right instrument panel support from vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Control Module > Component Information >
Locations > Page 7317
ACM Connectors
8. Disconnect two wire connectors from ACM.
9. Remove four bolts holding the ACM bracket assembly to floor.
10. Remove the ACM from vehicle.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET
THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD
NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET
INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM
For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with
the proper screws and tighten to 805 to 11.9 N.m (75 to 105 in. lbs.) torque. Do not connect battery
negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7322
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7323
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7324
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7325
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7326
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7327
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7328
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT: Airbag On-Off Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED
SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7329
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7330
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7331
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7332
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7333
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Air Bag Deactivation Switch > Component Information
> Technical Service Bulletins > Air Bag - On/Off Switches > Page 7334
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air
Bag Clockspring Replacement
Clockspring Assembly / Spiral Cable: Recalls Recall 04V480000: Air Bag Clockspring Replacement
Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan
1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth /
Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
Number : 04V480000 Recall Date : OCT 05, 2004
COMPONENT: Air Bags
Potential Number Of Units Affected : 955344
SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the
clockspring, which is located in the hub of the steering wheel.
CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning
lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a
reasonable amount of time.
REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles
or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an
extended lifetime warranty under which it will replace the clockspring at no charge if it fails.
DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on
their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at
1-800-853-1403.
NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension
Technical Service Bulletin # D17 Date: 041001
Recall - Clockspring Replacement/Warranty Extension
October 2004
Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty
Models 1998-2000 (NS)
Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country
NOTE:
This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed
control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative
driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP
function.
Note:
Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to
service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with
speed control and radio controls. Additional clockspring assemblies may be ordered as necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 7347
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed
a copy of their vehicle (VIN) list with the dealer recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 7348
Customer Services Field Operations Daimler Chrysler Corporation
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
IMPORTANT:
If an owner requests this recall service on a minivan that has more than 70,000 miles and an
AIRBAG light that operates normally even though the owner letter clearly states that no action is
necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3
of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present.
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 7349
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches and
steering wheel mounted radio controls (if equipped) (Figure 2).
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 7350
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multi-function switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches and steering
wheel mounted radio controls (if equipped) (Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 7351
between the airbag module and the steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > D17 > Oct > 04 > Recall - Clockspring
Replacement/Warranty Extension > Page 7352
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > NHTSA02V293000 > Nov > 02 > Recall 02V293000:
Clockspring Assembly Replacement
Clockspring Assembly / Spiral Cable: Recalls Recall 02V293000: Clockspring Assembly
Replacement
DEFECT: On certain minivans, the clockspring assembly may have been wound incorrectly during
the vehicle assembly process. This condition will cause illumination of the air bag warning lamp,
and could eventually cause the driver's air bag to become inoperative.
REMEDY: Dealers will replace the clockspring assembly on all vehicles with 70,000 miles or less.
An extended lifetime warranty will also be given for this component for all affected vehicles,
regardless of mileage. DaimlerChrysler will also reimburse owners who have paid to have the
clockspring replaced on their vehicles. The manufacturer has reported that owner notification
began Nov. 18, 2002. Owners should contact DaimlerChrysler at 1-800-853-1403.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement
Technical Service Bulletin # B24 Date: 021101
Recall - Clockspring Inspection/Replacement
November, 2002
Safety Recall No. B24 - Clockspring/Lifetime Warranty
Effective immediately, all repairs on involved vehicles are to be performed according to this recall.
Technical Service Bulletin 08-011-02 is being cancelled for 1996 through 1998 model year
vehicles.
Models:
1996-1998 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles built through February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject:
The clockspring on about 1,475,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical connection. This could cause the driver's airbag, horn and/or
speed control (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which
can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
clockspring for the vehicle to be serviced may be determined by:
> Using the part code in the third column of the VIN list along with the table shown (involved
dealers);
> Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers); or
> Entering the VIN into DIAL VIP System (sales code information) along with the table (all dealers):
Note:
Sales Code NHM is for Speed Control.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control and ONE (1) Clockspring Assembly to
service vehicles without speed control. Additional clockspring assemblies may be ordered as
necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement > Page 7361
service completions and provide dealer payments.
Use one of the labor operation numbers and time allowances shown.
Add the cost of the clockspring assembly plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List
All dealers will receive a copy of the dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of
their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN)
sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in
arranging for service of involved vehicles.
Dial System Function 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RDB24"
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair
Vehicles Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement > Page 7362
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRBIII, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches (if
equipped) (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement > Page 7363
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement > Page 7364
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multifunction switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches (if equipped)
(Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched between the airbag module and the
steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 N.m).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement > Page 7365
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Recalls: > B24 > Nov > 02 > Recall - Clockspring
Inspection/Replacement > Page 7366
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning
Lamp ON Intermittently/Constantly
Clockspring Assembly / Spiral Cable: Customer Interest Air Bags - Warning Lamp ON
Intermittently/Constantly
NUMBER: 08-011-02
GROUP: Electrical
DATE: Aug. 19, 2002
SUBJECT: Air Bag Warning Indicator Lamp On
OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either
intermittently or constantly.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Market)
SYMPTOM/CONDITION:
The air bag warning indicator lamp may be on intermittently or constantly.
DIAGNOSIS:
If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is
DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body
Diagnostic Manual leads to replace the clockspring because of high resistance, perform the
following additional diagnostic procedure.
DISCUSSION:
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing and replacing any component. When
diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool
8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test
components and wiring. Only replace and/or repair the component or wiring that has been
identified with the 8310 Airbag Load Tool and the DRBIII(R).
NOTE:
AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310
AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT.
NOTE:
RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG
WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN
INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE
CLOCKSPRING FOR THE DRIVER'S SQUIB.
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning
Lamp ON Intermittently/Constantly > Page 7372
EQUIPMENT POSSIBLY REQUIRED:
REPAIR PROCEDURE:
1. Determine if the Driver Squib Circuit Open DTC is active or stored.
a. If DTC is active proceed to step 2.
b. If DTC is stored proceed to step 3.
2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring,
verify the DTC remains by turning the steering wheel to the full left lock position, back to the full
right lock position, and then back to the centered position. This can be verified by using the 8310
Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From
the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics,
select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation
from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present
at this time, proceed to step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock
position, back to the full right lock position, and then back to the centered position and verify that
the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the
8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R).
From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002
Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor
Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to
lock, continue with step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 08-011-02 > Aug > 02 > Air Bags - Warning
Lamp ON Intermittently/Constantly > Page 7373
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7378
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7379
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7380
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7381
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7382
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > Customer Interest: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 7383
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag
Clockspring Replacement
Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan
1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth /
Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
Number : 04V480000 Recall Date : OCT 05, 2004
COMPONENT: Air Bags
Potential Number Of Units Affected : 955344
SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the
clockspring, which is located in the hub of the steering wheel.
CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning
lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a
reasonable amount of time.
REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles
or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an
extended lifetime warranty under which it will replace the clockspring at no charge if it fails.
DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on
their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at
1-800-853-1403.
NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension
Technical Service Bulletin # D17 Date: 041001
Recall - Clockspring Replacement/Warranty Extension
October 2004
Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty
Models 1998-2000 (NS)
Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country
NOTE:
This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed
control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative
driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP
function.
Note:
Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to
service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with
speed control and radio controls. Additional clockspring assemblies may be ordered as necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7393
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed
a copy of their vehicle (VIN) list with the dealer recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7394
Customer Services Field Operations Daimler Chrysler Corporation
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
IMPORTANT:
If an owner requests this recall service on a minivan that has more than 70,000 miles and an
AIRBAG light that operates normally even though the owner letter clearly states that no action is
necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3
of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present.
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7395
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches and
steering wheel mounted radio controls (if equipped) (Figure 2).
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7396
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multi-function switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches and steering
wheel mounted radio controls (if equipped) (Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7397
between the airbag module and the steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7398
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > NHTSA02V293000 > Nov > 02 > Recall 02V293000: Clockspring Assembly Replacement
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 02V293000:
Clockspring Assembly Replacement
DEFECT: On certain minivans, the clockspring assembly may have been wound incorrectly during
the vehicle assembly process. This condition will cause illumination of the air bag warning lamp,
and could eventually cause the driver's air bag to become inoperative.
REMEDY: Dealers will replace the clockspring assembly on all vehicles with 70,000 miles or less.
An extended lifetime warranty will also be given for this component for all affected vehicles,
regardless of mileage. DaimlerChrysler will also reimburse owners who have paid to have the
clockspring replaced on their vehicles. The manufacturer has reported that owner notification
began Nov. 18, 2002. Owners should contact DaimlerChrysler at 1-800-853-1403.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement
Technical Service Bulletin # B24 Date: 021101
Recall - Clockspring Inspection/Replacement
November, 2002
Safety Recall No. B24 - Clockspring/Lifetime Warranty
Effective immediately, all repairs on involved vehicles are to be performed according to this recall.
Technical Service Bulletin 08-011-02 is being cancelled for 1996 through 1998 model year
vehicles.
Models:
1996-1998 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles built through February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject:
The clockspring on about 1,475,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical connection. This could cause the driver's airbag, horn and/or
speed control (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which
can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
clockspring for the vehicle to be serviced may be determined by:
> Using the part code in the third column of the VIN list along with the table shown (involved
dealers);
> Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers); or
> Entering the VIN into DIAL VIP System (sales code information) along with the table (all dealers):
Note:
Sales Code NHM is for Speed Control.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control and ONE (1) Clockspring Assembly to
service vehicles without speed control. Additional clockspring assemblies may be ordered as
necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7407
service completions and provide dealer payments.
Use one of the labor operation numbers and time allowances shown.
Add the cost of the clockspring assembly plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List
All dealers will receive a copy of the dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of
their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN)
sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in
arranging for service of involved vehicles.
Dial System Function 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RDB24"
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair
Vehicles Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7408
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRBIII, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches (if
equipped) (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7409
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7410
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multifunction switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches (if equipped)
(Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched between the airbag module and the
steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 N.m).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7411
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7412
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON
Intermittently/Constantly
NUMBER: 08-011-02
GROUP: Electrical
DATE: Aug. 19, 2002
SUBJECT: Air Bag Warning Indicator Lamp On
OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either
intermittently or constantly.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Market)
SYMPTOM/CONDITION:
The air bag warning indicator lamp may be on intermittently or constantly.
DIAGNOSIS:
If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is
DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body
Diagnostic Manual leads to replace the clockspring because of high resistance, perform the
following additional diagnostic procedure.
DISCUSSION:
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing and replacing any component. When
diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool
8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test
components and wiring. Only replace and/or repair the component or wiring that has been
identified with the 8310 Airbag Load Tool and the DRBIII(R).
NOTE:
AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310
AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT.
NOTE:
RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG
WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN
INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE
CLOCKSPRING FOR THE DRIVER'S SQUIB.
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7417
EQUIPMENT POSSIBLY REQUIRED:
REPAIR PROCEDURE:
1. Determine if the Driver Squib Circuit Open DTC is active or stored.
a. If DTC is active proceed to step 2.
b. If DTC is stored proceed to step 3.
2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring,
verify the DTC remains by turning the steering wheel to the full left lock position, back to the full
right lock position, and then back to the centered position. This can be verified by using the 8310
Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From
the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics,
select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation
from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present
at this time, proceed to step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock
position, back to the full right lock position, and then back to the centered position and verify that
the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the
8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R).
From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002
Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor
Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to
lock, continue with step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7418
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7423
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7428
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7429
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7430
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7431
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7432
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Clockspring Assembly / Spiral
Cable: > 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7433
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Air Bags - Warning Lamp ON
Intermittently/Constantly
NUMBER: 08-011-02
GROUP: Electrical
DATE: Aug. 19, 2002
SUBJECT: Air Bag Warning Indicator Lamp On
OVERVIEW: This bulletin involves the air bag warning Indicator lamp coming on either
intermittently or constantly.
MODELS:
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Market)
SYMPTOM/CONDITION:
The air bag warning indicator lamp may be on intermittently or constantly.
DIAGNOSIS:
If the customer describes the above symptom/condition, the Diagnostic Trouble Code (DTC) is
DRIVER SQUIB CIRCUIT OPEN (active or stored), and the MDS2 or the appropriate Body
Diagnostic Manual leads to replace the clockspring because of high resistance, perform the
following additional diagnostic procedure.
DISCUSSION:
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing and replacing any component. When
diagnosing any airbag squib circuit DTC with a DRBIII(R), use of the Airbag Load Tool, special tool
8310, is required. The 8310 Airbag Load Tool, with the DRBIII(R) is used to isolate and test
components and wiring. Only replace and/or repair the component or wiring that has been
identified with the 8310 Airbag Load Tool and the DRBIII(R).
NOTE:
AIR BAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS BEEN REPLACED. USE OF THE DRBIII(R) AND THE 8310
AIRBAG LOAD TOOL WILL DETERMINE IF THE AIRBAG REQUIRES REPLACEMENT.
NOTE:
RECENT ANALYSIS OF RETURNED CLOCKSPRINGS HAS SHOWN THAT AN AIRBAG
WARNING INDICATOR LAMP MAY BE ON INTERMITTENTLY OR CONSTANTLY DUE TO AN
INCREASE OF RESISTANCE IN THE ELECTRICAL CONNECTION AT THE BASE OF THE
CLOCKSPRING FOR THE DRIVER'S SQUIB.
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7439
EQUIPMENT POSSIBLY REQUIRED:
REPAIR PROCEDURE:
1. Determine if the Driver Squib Circuit Open DTC is active or stored.
a. If DTC is active proceed to step 2.
b. If DTC is stored proceed to step 3.
2. If an active Driver Squib Circuit Open DTC is present and diagnosis leads to a bad clockspring,
verify the DTC remains by turning the steering wheel to the full left lock position, back to the full
right lock position, and then back to the centered position. This can be verified by using the 8310
Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R). From
the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002 Diagnostics,
select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance varies between 4.5 and 12.5 ohms during steering wheel rotation
from lock to lock, continue with step 2c. If resistance is less than 4.5 ohms, problem is not present
at this time, proceed to step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781M to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
3. If a stored Driver Squib Circuit Open DTC is present, turn the steering wheel to the full left lock
position, back to the full right lock position, and then back to the centered position and verify that
the driver's squib resistance does not vary above 12.5 ohms. This can be verified by using the
8310 Airbag Load Tool and monitoring the driver's airbag circuit resistance using the DRBIII(R).
From the DRBIII(R) Main Menu, select # 1 - DRBIII(R) Standalone, select # 1 - 1998 - 2002
Diagnostics, select # 1 - All, select # 6 - Passive Restraints, select # 1 - Airbag, select # 4 - Sensor
Display.
a. If the driver's squib resistance varies above 12.5 ohms during steering wheel rotation from lock
to lock, this indicates that the clockspring will need to be replaced. Center the steering wheel and
replace the clockspring using the procedure outlined in the MDS2 or the appropriate Service
Manual under Section 8M Passive Restraints, Removal and Installation, Clockspring. After
replacing the clockspring, proceed to step 4.
b. If the driver's squib resistance is 12.5 ohms or less during steering wheel rotation from lock to
lock, continue with step 3c.
c. Disconnect the two-way (yellow) wiring connector at the base of the clockspring. Apply
approximately 0.5 grams of dielectric grease part number 05013781AA to each terminal of the
connector. Reconnect the two-way (yellow) connector to the base of the clockspring.
d. Retest the driver's squib resistance while turning the steering wheel to the full left lock position,
back to the full right lock position, and then back to the centered position. If the resistance value is
now less than 4.5 ohms during the steering wheel rotation from lock to lock, then repair is
complete. Proceed to step 4. If not, proceed to next step.
e. If resistance is still greater than 4.5 ohms during steering wheel rotation from lock to lock, this
indicates that the clockspring will need to be replaced. Center the steering wheel and replace the
clockspring using the procedure outlined in the MDS2 or the appropriate Service Manual under
Section 8M Passive Restraints, Removal and Installation, Clockspring. After replacing the
clockspring, proceed to step 4.
4. Perform Airbag Verification Test VER-1A in the back of the appropriate Body Diagnostic manual.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-011-02 > Aug > 02 > Air Bags - Warning Lamp ON Intermittently/Constantly > Page 7440
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Airbag/Clock Spring - Service
NUMBER: 08-010-01
GROUP: Electrical
DATE: May 25, 2001
SUBJECT: Airbag/Clock Spring Service
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - 2002 (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1988 - 1993 (AG) Daytona
1988 - 1995 (AJ) Lebaron Coupe/Convertible
1990 (AL) Horizon/Omni
1988 - 1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1994 - 2002 (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - 2002 (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - 2002 (DN) Durango
2002 (DR) Ram Pickup
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
2001 - 2002 (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
2002 (KJ) Liberty
1993 - 2002 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2002 (PL) Neon
1997 - 2002 (PR) Prowler
2002 (PG) PT Cruiser (International Markets)
2001 - 2002 (PT) PT Cruiser
2001 - 2002 (RG) Chrysler Voyager (International Markets)
2001 - 2002 (RS) Town & Country/Caravan/Voyager
1996 - 2002 (SR) Viper
2001 - 2002 (ST) Sebring Coupe/Stratus Coupe
1997 - 2002 (TJ) Wrangler
2001 - 2002 (WG) Grand Cherokee (International Markets)
1999 - 2002 (WJ) Grand Cherokee
1995 - 2001 (XJ) Cherokee
1995 - 1998 (ZG) Grand Cherokee (International Markets)
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION:
Airbag
When servicing any airbag system, it is essential to follow the proper Service Manual and/or
Diagnostic Manual procedures for diagnosing, testing, and replacing of any component. When
diagnosing any airbag squib circuit Diagnostic Trouble Code (DTC) with a DRBIII(R), the use of the
Airbag Load Tool (Special Tool 8310 and 8443) is required. The Airbag Load Tool, used in
conjunction with the DRBIII(R) are used to isolate and test components and wiring for failure. Only
replace the component or wiring that has failed. This will reduce unnecessary cost to the customer
or DaimlerChrysler.
NOTE:
AIRBAG REPLACEMENT IS NOT REQUIRED EVERY TIME IT IS REMOVED OR WHEN
ANOTHER COMPONENT HAS FAILED. USE OF THE DRBIII(R) AND AIRBAG LOAD TOOL
WILL DETERMINE IF THE AIRBAG HAS FAILED AND REPLACEMENT IS NEEDED.
NOTE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7445
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7450
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7451
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7452
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7453
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7454
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 19-09-99 > Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 7455
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> NHTSA04V480000 > Oct > 04 > Recall 04V480000: Air Bag Clockspring Replacement
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 04V480000: Air Bag
Clockspring Replacement
Make / Models : Model/Build Years: Chrysler / Town and Country 1998-2000 Dodge / Caravan
1998-2000 Dodge / Grand Caravan 1998-2000 Plymouth / Grand Voyager 1998-2000 Plymouth /
Voyager 1998-2000 MANUFACTURER: DaimlerChrysler Corporation NHTSA CAMPAIGN ID
Number : 04V480000 Recall Date : OCT 05, 2004
COMPONENT: Air Bags
Potential Number Of Units Affected : 955344
SUMMARY: On certain minivans, the driver's air bag may become disabled due to a failure of the
clockspring, which is located in the hub of the steering wheel.
CONSEQUENCE: This condition will manifest itself through illumination of the air bag warning
lamp, and could eventually result in a driver's air bag open circuit, if the part is not replaced in a
reasonable amount of time.
REMEDY: Dealers will replace the clockspring assembly on all covered vehicles with 70,000 miles
or less. FOR THOSE VEHICLES WITH MORE THAN 70,000 MILES, DaimlerChrysler will offer an
extended lifetime warranty under which it will replace the clockspring at no charge if it fails.
DaimlerChrysler will also reimburse owners who have paid to have the clockspring replaced on
their vehicles. The recall began on October 12, 2004. Owners should contact DaimlerChrysler at
1-800-853-1403.
NOTES: DaimlerChrysler Recall NO. D17. Customers can contact The National Highway Traffic
Safety Administration's Auto Safety Hotline at 1-888-DASH-2-DOT (1-888-327-4236).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension
Technical Service Bulletin # D17 Date: 041001
Recall - Clockspring Replacement/Warranty Extension
October 2004
Dealer Service Instructions for: Safety Recall D17 - Clockspring/Lifetime Warranty
Models 1998-2000 (NS)
Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler Town & Country
NOTE:
This recall applies only to the above vehicles built after February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the VIP inquiry process.
Subject
The clockspring on about 1,290,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical components. This could cause the driver's airbag, horn, speed
control and/or steering wheel mounted radio controls (if equipped) to be inoperative. An inoperative
driver's airbag will not deploy, which can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
appropriate clockspring for the vehicle to be serviced is displayed on the DealerCONNECT VIP
function.
Note:
Sales Code NHM is for Speed Control and RDZ is for Steering Wheel Mounted Radio Controls.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control, ONE (1) Clockspring Assembly to
service vehicles without speed control and ONE (1) Clockspring Assembly to service vehicles with
speed control and radio controls. Additional clockspring assemblies may be ordered as necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DealerCONNECT Claim
Entry Screen located on the Service tab. Claims
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7465
submitted will be used by DaimlerChrysler to record recall service completions and provide dealer
payments.
Use one of the labor operation numbers and time allowances shown.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle list
All dealers will receive a copy of this dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS. DealerCONNECT will be updated to include this
recall in the near future.
Vehicle Lists, Global Recall System, VIP and Dealer Follow up
All involved vehicles have been entered into the DealerCONNECT Global Recall System (GRS)
and Vehicle Information Plus (VIP) for dealer inquiry as needed. Involved dealers were also mailed
a copy of their vehicle (VIN) list with the dealer recall notification letter.
GRS provides involved dealers with an updated VIN list of their incomplete vehicles. The owner's
name, address and phone number are listed if known. Completed vehicles are removed from GRS
within several days of repair claim submission.
To use this system, click on the "Service" tab and then click on "Global Recall System." Your
dealer's VIN list for each recall displayed can be sorted by: those vehicles that were unsold at
recall launch, those with a phone number, city, zip code, or VIN sequence.
Dealers must perform this repair on all unsold vehicles before retail delivery.
Dealers should also use the VIN list to follow up with all owners to schedule appointments for this
repair.
Recall VIN lists may contain confidential, restricted owner name and address information that was
obtained from the Department of Motor Vehicles of various states. Use of this information is
permitted for this recall only and is strictly prohibited from all other use.
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A generic copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification postcard to allow owners to update our
records if applicable.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair.
Additional Information
If you have any questions or need assistance in completing this action, please contact your Service
and Parts District Manager.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7466
Customer Services Field Operations Daimler Chrysler Corporation
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
IMPORTANT:
If an owner requests this recall service on a minivan that has more than 70,000 miles and an
AIRBAG light that operates normally even though the owner letter clearly states that no action is
necessary at this time, then to ensure customer satisfaction, dealers should perform Steps 2 and 3
of the service procedure to verify that the "Driver Squib Circuit Open" DTC is not present.
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRB III, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7467
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches and
steering wheel mounted radio controls (if equipped) (Figure 2).
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7468
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multi-function switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches and steering
wheel mounted radio controls (if equipped) (Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7469
between the airbag module and the steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 Nm).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> D17 > Oct > 04 > Recall - Clockspring Replacement/Warranty Extension > Page 7470
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> NHTSA02V293000 > Nov > 02 > Recall 02V293000: Clockspring Assembly Replacement
Clockspring Assembly / Spiral Cable: All Technical Service Bulletins Recall 02V293000:
Clockspring Assembly Replacement
DEFECT: On certain minivans, the clockspring assembly may have been wound incorrectly during
the vehicle assembly process. This condition will cause illumination of the air bag warning lamp,
and could eventually cause the driver's air bag to become inoperative.
REMEDY: Dealers will replace the clockspring assembly on all vehicles with 70,000 miles or less.
An extended lifetime warranty will also be given for this component for all affected vehicles,
regardless of mileage. DaimlerChrysler will also reimburse owners who have paid to have the
clockspring replaced on their vehicles. The manufacturer has reported that owner notification
began Nov. 18, 2002. Owners should contact DaimlerChrysler at 1-800-853-1403.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement
Technical Service Bulletin # B24 Date: 021101
Recall - Clockspring Inspection/Replacement
November, 2002
Safety Recall No. B24 - Clockspring/Lifetime Warranty
Effective immediately, all repairs on involved vehicles are to be performed according to this recall.
Technical Service Bulletin 08-011-02 is being cancelled for 1996 through 1998 model year
vehicles.
Models:
1996-1998 (NS) Dodge Caravan/Grand Caravan, Plymouth Voyager/Grand Voyager and Chrysler
Town & Country
NOTE:
This recall applies only to the above vehicles built through February 28, 1998 (MDH 0228XX).
IMPORTANT:
Some of the involved vehicles may be in dealer used vehicle inventory. Dealers should complete
this recall service on these vehicles before retail delivery. Dealers should also perform this recall on
vehicles in for service. Involved vehicles can be determined by using the DIAL VIP System.
Subject:
The clockspring on about 1,475,000 of the above vehicles may lose the electrical connection to the
steering wheel mounted electrical connection. This could cause the driver's airbag, horn and/or
speed control (if equipped) to be inoperative. An inoperative driver's airbag will not deploy, which
can result in increased injury to the driver in a frontal crash.
Repair
Vehicles with a failed clockspring or vehicles with 70,000 miles or LESS, must have the clockspring
assembly replaced.
Vehicles with more than 70,000 miles that have a properly functioning clockspring do NOT require
any repair action. Vehicles involved in this recall have a lifetime warranty on the clockspring
assembly.
NOTE:
This recall does NOT include replacement of other airbag system components. If other components
cause illumination of the airbag warning light, the associated repair costs are the owner's
responsibility.
Parts Information
Dealers should determine which clockspring is required for each vehicle at the time appointments
are scheduled to assure that the correct part is available when the customer arrives. The
clockspring for the vehicle to be serviced may be determined by:
> Using the part code in the third column of the VIN list along with the table shown (involved
dealers);
> Using the VIN and part number list electronically transmitted to DIAL System Function 53
(involved dealers); or
> Entering the VIN into DIAL VIP System (sales code information) along with the table (all dealers):
Note:
Sales Code NHM is for Speed Control.
Each dealer to whom vehicles in the recall were invoiced will receive TWO (2) Clockspring
Assemblies to service vehicles equipped with speed control and ONE (1) Clockspring Assembly to
service vehicles without speed control. Additional clockspring assemblies may be ordered as
necessary.
Completion Reporting and Reimbursement
Claims for vehicles that have been serviced must be submitted on the DIAL System. Claims
submitted will be used by DaimlerChrysler to record recall
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7479
service completions and provide dealer payments.
Use one of the labor operation numbers and time allowances shown.
Add the cost of the clockspring assembly plus applicable dealer allowance to your claim.
NOTE:
See the Warranty Administration Manual, Recall Claim Processing Section, for complete recall
claim processing instructions.
Parts Return
Not required.
Dealer Notification and Vehicle List
All dealers will receive a copy of the dealer recall notification letter by first class mail. Two
additional copies will be sent through the DCMMS, and the MDS2 will be updated to include this
recall in the near future. Each dealer to whom involved vehicles were invoiced will receive a list of
their involved vehicles. The vehicle list is arranged in Vehicle Identification Number (VIN)
sequence. Owners known to DaimlerChrysler are also listed. The lists are for dealer reference in
arranging for service of involved vehicles.
Dial System Function 53 and VIP
All involved vehicles have been entered to DIAL System Functions 53 and VIP for dealer inquiry as
needed.
Function 53 provides involved dealers with an updated VIN list of their incomplete vehicles. The
customer name, address and phone number are listed if known. Completed vehicles are removed
from Function 53 within several days of repair claim submission. To use this system, type "53" at
the "ENTER FUNCTION" prompt, then type "0RDB24"
Owner Notification and Service Scheduling
All involved vehicle owners known to DaimlerChrysler are being notified of the service requirement
by first class mail. They are requested to schedule appointments for this service with their dealers.
A copy of the owner letter is included.
Enclosed with each owner letter is an Owner Notification Form. The involved vehicle and recall are
identified on the form for owner or dealer reference as needed.
Dealers are encouraged to consider alternative scheduling and servicing approaches for this recall.
This repair does not require hoists or other full service facility special equipment and is a
DaimlerChrysler Mobile Service approved repair
Vehicles Not Available
If a vehicle is not available for service, let us know by filling out the pre-addressed Owner
Notification Form or describe the reason on a postcard and mail to:
DaimlerChrysler Corporation CIMS 482-00-85 800 Chrysler Drive East Auburn Hills, Michigan
48326-2757
Additional Information
If you have any questions or need assistance in completing this action, please contact your Zone
Service Office.
Service Procedure
1. If the vehicle has LESS than 70,000 miles, the clockspring assembly MUST be replaced even if
it is functioning properly. Proceed to Step 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7480
2. Connect the DRBIII scan tool to the vehicle diagnostic connector and turn the ignition key to the
ON position.
3. Using the DRBIII, check for Airbag System Diagnostic Trouble Codes (DTC).
> If the DTC "DRIVER SQUIB CIRCUIT OPEN" is present (either active or stored), the clockspring
assembly MUST be replaced. Erase the DTC and continue with Step 4.
> If there are no DTC's or if any other airbag system DTC is present, the recall service procedure
does not apply. Diagnosis and repairs are the owner's responsibility.
4. Place the front wheels in the straight-ahead position.
5. Disconnect the negative battery cable.
NOTE:
To enhance customer satisfaction, remember to reset the clock when you have completed the
service procedure.
6. From the backside of the steering wheel, remove the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1).
7. Pull the airbag module away from the steering wheel far enough to access the wire harness
connectors on the back of the airbag module.
8. Disconnect the clockspring horn switch wire harness connector from the horn switch wire
connector on the back of the airbag module (Figure 2).
9. Disconnect the clockspring airbag wire harness connector (Figure 2) from the back of the airbag
module by firmly grasping and pulling, or gently prying, the connector.
NOTE:
Do NOT pull on the clockspring wire harness to disengage the connector from the airbag module
connector receptacle.
10. Disconnect the clockspring wire harness connectors from the speed control switches (if
equipped) (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7481
11. Remove the airbag module and set it aside.
12. Remove the steering wheel nut.
13. Remove the steering wheel damper from the steering wheel (if equipped).
14. Remove the steering wheel from the steering column using a steering wheel puller (Special
Tool C-3428-B).
15. Remove the three (3) screws that attach the upper and lower shrouds to the steering column,
then remove the shrouds from the steering column (Figure 3).
16. Disconnect the wiring harness connectors from the clockspring assembly (Figure 4).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7482
17. Remove the clockspring from the multi-function switch by depressing the two tabs on the
clockspring (Figure 5). Discard the clockspring assembly.
18. Slide the new clockspring over the steering column shaft until the clockspring latches engage
the multifunction switch housing (Figure 5).
19. Connect the wire harness connectors to the clockspring assembly (Figure 4).
20. Install the upper and lower shrouds onto the steering column (Figure 3). Tighten the screws
securely.
21. Install the steering wheel onto the steering column shaft.
22. Install the steering wheel damper (if equipped).
23. Install the steering wheel retaining nut. Tighten the nut to 45 ft-lbs (61 N.m).
24. Connect the clockspring wire harness connectors to the speed control switches (if equipped)
(Figure 2).
25. Connect the clockspring airbag wire harness connector to the back of the airbag module
(Figure 2).
26. Connect the clockspring horn switch wire harness connector to the horn switch wire connector
on the back of the airbag module (Figure 2).
27. Install the airbag module onto the steering wheel. Make sure that the clockspring wire
harnesses in the steering wheel hub area are not pinched between the airbag module and the
steering wheel.
28. From the backside of the steering wheel, install the three (3) screws that secure the driver's
airbag module to the steering wheel (Figure 1). Tighten the screws to 100 in-lbs (11 N.m).
29. With the ignition switch in the ON position, connect the negative battery cable.
30. From outside the vehicle, turn the ignition switch to the OFF position for about 10 seconds and
then turn it back to the ON position.
31. Observe the airbag warning light in the instrument cluster. It should illuminate for 6-8 seconds
and then go out.
NOTE:
If the airbag warning light fails to light or lights and stays on, there is a system malfunction. Refer to
the proper Body Diagnostic Procedures manual to diagnose and repair the problem.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7483
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> B24 > Nov > 02 > Recall - Clockspring Inspection/Replacement > Page 7484
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Technical Service Bulletins > All Other Service Bulletins for Clockspring Assembly / Spiral Cable:
> 08-010-01 > May > 01 > Airbag/Clock Spring - Service > Page 7489
TECHNICIANS SHOULD RECORD ALL STORED AND ACTIVE AIRBAG SYSTEM FAULT
CODES ON THE REPAIR ORDER.
Clock Springs
Recent analysis of returned clock springs have indicated that prior service may have contributed to
the clock spring's failure.
^ Do not use silicone or any other lubricant spray on or near the clock spring. Lubricants are often
used in the clock spring area of the steering column to eliminate noise. Lubricants may have an
adverse effect on the clock spring.
^ Clock spring centering. Any repair that may disrupt the positioning of the steering wheel with the
front wheels will require that the clock spring be centered. This includes clock spring replacement,
steering column service, HVAC service, steering gear service, and front suspension crossmember
service. Refer to the appropriate Service Manual for the clock spring centering procedure.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Component Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Component Locations > Page 7492
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Page 7493
Clockspring Assembly / Spiral Cable: Description and Operation
SYSTEM OPERATION
The clockspring is snapped into a plastic mounting platform on the steering column behind the
steering wheel. The clockspring is used to maintain a continuous electrical circuit between the
wiring harness and the driver's airbag module. This assembly consists of a flat ribbon like
electrically conductive tape which winds and unwinds with the steering wheel rotation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Page 7494
Clockspring Assembly / Spiral Cable: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Page 7495
Clockspring Assembly / Spiral Cable: Adjustments
CLOCKSPRING CENTERING PROCEDURE
If the rotating tape (wire coil) in the clockspring is not positioned properly with the steering wheel
and the front wheels, the clockspring may fail. The following procedure MUST BE USED to center
the clockspring if it is not known to be properly positioned, or if the front wheels were moved from
the straight ahead position.
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIRBAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
1. Adjust the steering wheel so that the tires are in a straight ahead position. 2. Disconnect and
isolate battery negative cable. Allow at least two minutes for the reserve capacitor in the ACM to
discharge. 3. Remove Driver Airbag Module from steering wheel. 4. Disconnect wire connectors
from back of airbag module. 5. Remove steering wheel.
Clockspring Locking Tabs
6. Depress the two plastic locking pins to disengage lock mechanism. 7. With lock mechanism
disengaged, rotate the clockspring rotor clockwise until the rotor stops. Do not apply excessive
force. 8. From the end of travel, rotate the rotor three turns counterclockwise. The wires should end
up at the top. Release locking pins to engage
clockspring lock mechanism.
9. Install steering wheel and airbag.
10. Do not connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Page 7496
Clockspring Assembly / Spiral Cable: Service and Repair
WARNING: DISCONNECT AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE
BEGINNING AIR- BAG SYSTEM COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE
THE AIRBAG SYSTEM. FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN
ACCIDENTAL AIRBAG DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM
CAPACITOR TO DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG
COMPONENTS.
REMOVAL 1. Position steering wheel and front wheels straight ahead. 2. Release hood latch and
open hood. 3. Disconnect and isolate battery negative cable. Allow at least two minutes for the
reserve capacitor in the ACM to discharge.
Airbag/Horn Switch
4. Remove driver airbag from steering wheel. 5. Disconnect wire connectors from back of airbag
module.
6. Remove steering wheel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Clockspring Assembly / Spiral Cable, Air Bag >
Component Information > Locations > Page 7497
7. Remove steering column shrouds. 8. Disconnect 2-way and 4-way connectors between the
clockspring and the instrument panel wiring harness.
Clockspring Locking Tabs
9. Remove clockspring from housing assembly by depressing the two tabs on the clockspring.
INSTALLATION For installation, reverse the above procedures. Do not connect battery negative
cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Impact Sensor > Component Information > Testing
and Inspection
Impact Sensor: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Air Bag Systems > Malfunction Lamp / Indicator, Air Bag > Component
Information > Testing and Inspection
Malfunction Lamp / Indicator: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time
Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED
JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 JA Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1999 - 2000 (WJ) Grand Cherokee
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 7508
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 7509
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 7510
PARTS REQUIRED:
POLICY: Customer Satisfaction
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 7511
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Child Seat > Component Information > Technical Service Bulletins > Child
Seat - Tether Anchor Part Numbers & Labor Time > Page 7512
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7517
Air Bag Control Module: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7518
Air Bag Control Module: Description and Operation
SYSTEM OPERATION
The Airbag Control Module (ACM) contains the impact sensor and energy reserve capacitor. The
ACM monitors the system to determine the system readiness. The ACM contains on-board
diagnostics and will light the AIRBAG warning lamp in the message center when a problem occurs.
The driver and passenger airbag system is a safety device designed to reduce the risk of fatality or
serious injury, caused by a frontal impact of the vehicle.
The impact sensor provides verification of the direction and severity of the impact. One impact
sensor is used. It is located inside the Airbag Control Module (ACM) which is mounted on a
bracket, just forward of the center console. The impact sensor is an accelerometer that senses
deceleration. The deceleration pulses are sent to a microprocessor which contains a decision
algorithm. When an impact is severe enough to require airbag protection, the ACM micro processor
sends a signal that completes the electrical circuit to the driver and passenger airbags. The sensor
is calibrated for the specific vehicle and reacts to the severity and direction of the impact.
Airbag Module Locations
Driver And Passenger Airbag Modules The Driver Airbag Module is located in the center of the
steering wheel. The Passenger Airbag Module is located in the instrument panel above the glove
box. The Driver Airbag Module cover contains the horn switch, inflator device, and a fabric bag.
The airbag cover/horn switch is serviced separately from the inflator and bag components. The
Passenger Airbag Module is serviced as an assembly.
WARNING: WHEN THE AIRBAG SYSTEM IS DEPLOYED BECAUSE OF A COLLISION, THE
FOLLOWING MUST BE REPLACED: COMPLETE STEERING COLUMN ASSEMBLY
- LOWER STEERING COUPLER
- STEERING WHEEL
- STEERING COLUMN CLOCKSPRING
- DRIVER AIRBAG COVER/HORN SWITCH
- DRIVER AIRBAG MODULE
- PASSENGER AIRBAG MODULE
- UPPER INSTRUMENT PANEL WITH PAD.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7519
Air Bag Control Module: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7520
Air Bag Control Module: Service and Repair
WARNING: THE ACM CONTAINS THE IMPACT SENSOR WHICH ENABLES THE SYSTEM TO
DEPLOY THE AIRBAGS. TO AVOID ACCIDENTAL DEPLOYMENT NEVER CONNECT ACM
ELECTRICALLY TO THE SYSTEM WHILE VEHICLE BATTERY IS CONNECTED. DISCONNECT
AND ISOLATE THE BATTERY NEGATIVE CABLE BEFORE BEGINNING ANY AIRBAG SYSTEM
COMPONENT SERVICE PROCEDURES. THIS WILL DISABLE THE AIRBAG SYSTEM.
FAILURE TO DISCONNECT THE BATTERY COULD RESULT IN ACCIDENTAL AIRBAG
DEPLOYMENT AND POSSIBLE PERSONAL INJURY. ALLOW SYSTEM CAPACITOR TO
DISCHARGE FOR TWO MINUTES BEFORE REMOVING AIRBAG COMPONENTS.
REMOVAL 1. Disconnect and isolate battery negative cable. Allow at least two minutes for the
reserve capacitor in the Airbag Control Module (ACM) to
discharge.
2. Remove forward lower console from instrument panel.
Heat Duct
3. Remove screw holding lower heat duct to instrument panel support. 4. Remove heat duct from
instrument panel.
5. Remove two bolts holding top of right support to instrument panel. 6. Remove two bolts holding
bottom of right support to floor pan. 7. Separate right instrument panel support from vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Relays and Modules - Restraint Systems > Air Bag Control Module >
Component Information > Locations > Page 7521
ACM Connectors
8. Disconnect two wire connectors from ACM.
9. Remove four bolts holding the ACM bracket assembly to floor.
10. Remove the ACM from vehicle.
INSTALLATION
WARNING: DO NOT REMOVE THE BOLTS HOLDING THE ACM TO THE ACM BRACKET
THESE BOLTS ARE SAFETY TORQUED AT THE MANUFACTURING FACILITY AND SHOULD
NOT BE REMOVED FOR ANY REASON. THE NEW ACM WILL COME WITH A NEW BRACKET
INSTALLED.
CAUTION: USE CORRECT SCREWS WHEN INSTALLING THE ACM
For installation, reverse the above procedures. Attach the ACM bracket assembly to vehicle with
the proper screws and tighten to 805 to 11.9 N.m (75 to 105 in. lbs.) torque. Do not connect battery
negative cable. Refer to Diagnosis and Testing for Airbag System Test procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Air Bag(s) Arming and Disarming > System
Information > Service and Repair > Air Bag Disarming > Page 7528
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation
Child Seat Tether Attachment: Technical Service Bulletins Restraints - Child Seat Tether
Installation
NUMBER: 23-029-08
GROUP: Body
DATE: October 24, 2008
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. B, DATED
NOVEMBER 24, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT REVISIONS.
DEALERS PLEASE NOTE, THIS IS REIMBURSABLE REGARDLESS OF VEHICLE AGE OR
MILEAGE.
SUBJECT: Child Seat Tether Anchor Installation
OVERVIEW: This bulletin describes procedures to install Child Seat Tether Anchors based on
Customer Request.
NOTE:
Dealers are encouraged to honor any customers request for the installation of the Child Seat
Tether Anchors and Dealer reimbursement will be made by Chrysler regardless of vehicle age or
mileage. See the Warranty Policy and Procedure Manual and or Warranty Bulletin D-08-33 for
reimbursement detail.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shawdow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7534
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
2000 (TJ) Wrangler
1999 - 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year and later. Tether straps improve
the performance of child restraints in collisions. Because of the publicity that has accompanied the
"Fit for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware.
Chrysler is offering child seat tether anchors for the selected vehicles listed above. Each tether
anchor is packaged in a kit containing all necessary parts and a detailed instruction sheet.
NOTE:
This bulletin is provided to identify the parts and labor operation numbers necessary to install a
Child Seat Tether Anchor. Each dealer is encouraged to install these kits based on customer
request and Chrysler will reimburse any Chrysler / Dodge / or Jeep dealer installing these kits
regardless of vehicle age or mileage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7535
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7536
PARTS REQUIRED:
POLICY: Customer Satisfaction, Reimbursable regardless of mileage or age.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7537
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7538
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7539
TIME ALLOWANCE:
FAILURE CODE:
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7540
Child Seat Tether Attachment: Technical Service Bulletins Child Seat Tether Anchor - Labor/Parts
Identification
NUMBER: 23-35-99 Rev. A
GROUP: Body
DATE: Oct. 1, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-35-99 DATED
SEPTEMBER 3, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE CHANGES IN SOME TIME
ALLOWANCES.
SUBJECT: Child Seat Tether Anchors
NOTE:
THIS BULLETIN DOES NOT APPLY TO DAIMLERCHRYSLER CANADA DEALERS.
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) LeBaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2000 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
1999 - 2000 (WJ) Grand Cherokee
1989 - 2000 (XJ) Cherokee/Wagoneer
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION
User-ready child restraint tether strap anchors will be provided in passenger cars in the 2000 Model
Year, and in light truck in the 2001 Model Year. Tether straps improve the performance of child
restraints in collisions. Because of the publicity that has accompanied the "Fit for a kid" Program,
owners of earlier products are expected to approach dealers for the free provision and installation
of the anchor hardware. DaimlerChrysler Corporation is offering child seat tether anchors for the
selected vehicles listed above. Each tether anchor is packaged in a kit containing all necessary
parts and a
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7541
detailed instruction sheet.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7542
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7543
POLICY: Customer Satisfaction
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7544
TIME ALLOWANCE:
Failure Code: CG - Customer Satisfaction
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7545
Child Seat Tether Attachment: Technical Service Bulletins Child Seat - Tether Anchor Part
Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED
JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 JA Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1999 - 2000 (WJ) Grand Cherokee
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7546
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7547
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7548
PARTS REQUIRED:
POLICY: Customer Satisfaction
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7549
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Child Restraint > Child Seat Tether Attachment >
Component Information > Technical Service Bulletins > Restraints - Child Seat Tether Installation > Page 7550
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > Recalls for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat Belt May Become
Inoperative
Seat Belt: Recalls Recall 02V076000: Seat Belt May Become Inoperative
Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat
belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat
occupant may not be properly restrained, increasing the risk of personal injury.
Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat
belt assemblies. The manufacturer has reported that owner notification is expected to begin during
June 2002. Owners who do not receive the free remedy within a reasonable time should contact
DaimlerChrysler at 1-800-853-1403.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Seat Belt Systems > Seat Belt > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Seat Belt: > NHTSA02V076000 > Mar > 02 > Recall 02V076000: Seat
Belt May Become Inoperative
Seat Belt: All Technical Service Bulletins Recall 02V076000: Seat Belt May Become Inoperative
Defect: On certain minivans, some trim material can loosen and drop into the rear outboard seat
belt assembly, causing the seat belt to become inoperative. In the event of a crash, the seat
occupant may not be properly restrained, increasing the risk of personal injury.
Remedy: Dealers will replace the trim with foam blockers and inspect and replace all 3rd row seat
belt assemblies. The manufacturer has reported that owner notification is expected to begin during
June 2002. Owners who do not receive the free remedy within a reasonable time should contact
DaimlerChrysler at 1-800-853-1403.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag - On/Off Switches
NUMBER: 08-025-01
GROUP: Electrical
DATE: Nov. 23, 2001
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-037-99, DATED
NOVEMBER 12, 1999, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1999 TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-00004). ALL
REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS,
PARTS, AND 2001 MODEL YEAR PROCEDURES.
NOTE:
THIS BULLETIN DOES NOT APPLY TO DIAMLERCHRYSLER CANADA DEALERS.
SUBJECT: Airbag On-Off Switches
MODELS:
1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan
1995 - **2001** (AB) Ram Van/Wagon
1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) Lebaron Coupe/Convertible
1994 - **2001** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1994 - **2001** (BR/BE) Ram Pickup
1995 - 1996 (B7) Stealth
1998 - **2001** (DN) Durango
1995 - 2000 (FJ) Avenger/Sebring/Talon
1995 - 2000 (JA) Breeze/Cirrus/Stratus
**2001** (JR) Sebring Sedan/Stratus Sedan/Sebring Convertible
1996 - 2000 (JX) Sebring Convertible
1993 - **2001** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - **2001** (PL) Neon
1997 (PR) Prowler
**2001 (PT) PT Cruiser**
**2001** (RS) Town & Country/Caravan/Voyager
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7569
1996 - 1997 (SR) Viper
**2001 - 2002 (ST) Sebring Coupe/Stratus Coupe**
1997 - 2001** (TJ) Wrangler
1999 - **2001** (WJ) Grand Cherokee
1997 - **2001** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
NOTE:
**SOME 2001 MODEL YEAR PACKAGES (AN/AN84/DN/JR/LH/PL/PT/RS/TJ) REQUIRE
OCCUPANT RESTRAINT CONTROLLER (ORC) CONFIGURATION USING THE DRB III(R) AS
DETAILED IN EACH VEHICLE SPECIFIC PACKAGE.**
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. The switches are packaged in a kit containing all necessary parts (except as indicated) and
a detailed instruction sheet. Under the National Highway Traffic Safety Administration's rule,
consumers will be authorized for on-off switches by claiming they meet any of several criteria.
Airbag on-off switches must not be installed without the vehicle owner presenting the NHTSA
authorization letter. For more information concerning the authorization process and/or the
authorization letter call NHTSA's Auto Safety Hotline at 1-800-424-9393. We encourage you
(dealer) to install these switches when the customer is interested in doing so and has the
necessary NHTSA authorization.
NOTE:
FOR SOME 2000 MODEL YEAR APPLICATIONS (AB/AN/AN84/DN/JA/NS) **AND SOME 2001
CARRYOVER APPLICATIONS (AB/BR/WJ/XJ)**, A NEW OWNER'S MANUAL INSERT IS
REQUIRED, P/N 05013528AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG
SWITCH KIT. THE NEW INSERT IS ORANGE, AND MUST BE PRESENTED TO THE
CUSTOMER IN PLACE OF THE YELLOW ONE, P/N 05013517AA, THAT WILL COME IN THE
AIRBAG KIT.
**FOR SOME 2001 MODEL YEAR APPLICATIONS (WITH J1850 BUS,
AN/AN84/DN/JR/LH/PL(PT/RS/TJ) A NEW OWNER'S MANUAL INSERT IS REQUIRED, P/N
05016025AA, AND MUST BE ORDERED IN ADDITION TO THE AIRBAG SWITCH KIT. THE
NEW INSERT MUST BE PRESENTED TO THE CUSTOMER AFTER INSTALLATION.**
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7570
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7571
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7572
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7573
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7574
PARTS REQUIRED:
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have~
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available in the "Forms Folder" under "TSB/Recall" tab of MDS2 and printed on
your dealership letterhead. keep a copy for your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7575
Air Bag Deactivation Switch: Technical Service Bulletins Air Bag System - ON-OFF Switch
Availibility
NO: 08-17-98 Rev. C
GROUP: Electrical
DATE: Dec. 30, 1998
SUBJECT: Airbag On-Off Switches
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-17-98 Rev. B DATED
SEPTEMBER 18, 1998 WHICH SHOULD BE REMOVED FROM YOUR FILES. ADDITIONAL
MODELS HAVE BEEN ADDED. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS**.
MODELS:
**1990 - 1995 (AA) Spirit/Acclaim/Lebaron Sedan**
1995 - **1999** (AB) Ram Van/Wagon
**1990 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon**
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/Convertible
1994 -**1999** (AN) Dakota
1990 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1991 - 1995 (AS) Town & Country/Caravan/Voyager
**1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue**
1994 - **1999** (BR) Ram Pickup
**1995 - 1996 (B7) Stealth**
1998 - **1999** (DN) Durango
**1995 - 1999 (FJ) Avenger/Sebring/Talon**
1995 - **1999** (JA) Breeze/Cirrus/Stratus
1996 - **1999** (JX) Sebring Convertible
1993 -**1999** (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - **1999** (NS) Town & Country/Caravan/ Voyager
1995 - **1999** (PL) Neon
1996 - 1997 (SR) Viper
1997 - **1999** (TJ) Wrangler
1997 - **1999** (XJ) Cherokee
1993 - 1998 (ZJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND PROCEDURES NECESSARY
TO DEACTIVATE AIRBAGS AUTHORIZED BY NHTSA. AIRBAG DEACTIVATION IS A
CUSTOMER PAY PROCEDURE, NOT COVERED UNDER THE PROVISIONS OF THE
WARRANTY. THE COMPONENT PARTS ARE COVERED UNDER THE APPROPRIATE MOPAR
PART WARRANTY.
DISCUSSION:
DaimlerChrysler Corporation is now offering airbag on-off switches for the selected vehicles listed
above. Other applicable passenger vehicles will be announced as soon as the switches are
available. The switches are packaged in a kit containing all necessary parts (except as indicated)
and a detailed instruction sheet.
Under the National Highway Traffic Safety Administration's rule, consumers will be authorized for
on-off switches by claiming they meet any of several criteria. Airbag on-off switches must not be
installed without the vehicle owner presenting the NHTSA authorization letter. For more information
concerning the authorization process and/or the authorization letter call NHTSA's Auto Safety
Hotline at 1-800-424-9393.
We encourage you (dealer) to install these switches when the customer is interested in doing so
and has the necessary NHTSA authorization.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7576
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7577
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7578
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7579
PARTS REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7580
NOTE:
SOME INSTRUCTION SHEETS FOR THE 1999 MODELS LIST ONLY 1998 MODELS ON THE
COVER PAGE. THE 1998 KITS CAN BE USED ON ALL 1999 CARRY-OVER VEHICLES.
DEACTIVATION/DOCUMENTATION PROCEDURE:
1. Before you install any airbag on-off switch for owners of air bag equipped vehicles, the owner
must present to you an "Authorization Form" from the U.S. Department of Transportation National
Highway Traffic Safety Administration (NHTSA), certifying the specific vehicle by its vehicle
identification number. The authorization applies only to the vehicle identified and not to other
vehicles that the owner may have.
2. The owner must complete the "Authorization to Install Air Bag On-Off Switch Release
Agreement Form" available on T.I.L. and printed on your dealership letterhead. Keep a copy for
your records and make a copy for the vehicle owner.
3. Complete the NHTSA authorization form, and return it to NHTSA within seven days, making
copies for the owner's and your records.
NOTE:
ALL DEALER OWNED USED VEHICLES SHOULD BE INSPECTED FOR PROPER AIRBAG
OPERATION, i.e. NOT DEACTIVATED, PRIOR TO RESALE.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Air Bag Deactivation Switch
> Component Information > Technical Service Bulletins > Air Bag - On/Off Switches > Page 7581
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Restraint Systems > Sensors and Switches - Restraint Systems > Impact Sensor >
Component Information > Testing and Inspection
Impact Sensor: Testing and Inspection
Chrysler does not provide a procedure to retrieve trouble codes without a scan tool.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and
Operation
Antenna: Description and Operation
SYSTEM OPERATION
All models use a fixed-length stainless steel rod-type antenna mast, installed at the right front
fender of the vehicle. The antenna mast is connected to the center wire of the coaxial antenna
cable, and is not grounded to any part of the vehicle.
To eliminate static, the antenna base must have a good ground. The coaxial antenna cable shield
(the outer wire mesh of the cable) is grounded to the antenna base and the radio chassis.
The antenna coaxial cable has an additional disconnect, located near the right end of the
instrument panel. This additional disconnect allows the instrument panel assembly to be removed
and installed without removing the radio.
The factory-installed Electronically Tuned Radios (ETRs) automatically compensate for radio
antenna trim. Therefore, no antenna trimmer adjustment is required or possible when replacing the
receiver or the antenna.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Description and
Operation > Page 7589
Antenna: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR-BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
The following four tests are used to diagnose the antenna with an ohmmeter:
- Test 1 - Mast to ground test - Test 2 - Tip-of-mast to tip-of-conductor test - Test 3 - Body ground
to battery ground test - Test 4 - Body ground to coaxial shield test.
Antenna Tests
The ohmmeter test lead connections for each test are shown in Antenna Tests .
NOTE: This model has a two-piece antenna coaxial cable. Tests 2 and 4 must be conducted in two
steps to isolate a coaxial cable problem; from the coaxial cable connection under the right end of
the instrument panel near the right cowl side panel to the antenna base, and then from the coaxial
cable connection to the radio chassis connection.
Test 1 Test 1 determines if the antenna mast is insulated from the base. Proceed as follows: 1.
Unplug the antenna coaxial cable connector from the radio chassis and isolate. 2. Connect one
ohmmeter test lead to the tip of the antenna mast. Connect the other test lead to the antenna base.
Check for continuity. 3. There should be no continuity If continuity is found, replace the faulty or
damaged antenna base and cable assembly.
Test 2 Test 2 checks the antenna for an open circuit as follows: 1. Unplug the antenna coaxial
cable connector from the radio chassis. 2. Connect one ohmmeter test lead to the tip of the
antenna mast. Connect the other test lead to the center pin of the antenna coaxial cable connector.
3. Continuity should exist (the ohmmeter should only register a fraction of an ohm). High or infinite
resistance indicates damage to the base and cable
assembly. Replace the faulty base and cable, if required.
Test 3 Test 3 checks the condition of the vehicle body ground connection. This test should be
performed with the battery positive cable removed from the battery Disconnect both battery cables,
the negative cable first. Reconnect the battery negative cable and perform the test as follows: 1.
Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to the battery
negative post. 2. The resistance should be less than (1) ohm. 3. If the resistance is more than (1)
ohm, check the braided ground strap connected to the engine and the vehicle body for being loose,
corroded, or
damaged. Repair the ground strap connection, if required.
Test 4 Test 4 checks the condition of the ground between the antenna base and the vehicle body
as follows: 1. Connect one ohmmeter test lead to the vehicle fender. Connect the other test lead to
the outer crimp on the antenna coaxial cable connector. 2. The resistance should be less then (1)
ohm. 3. If the resistance is more then (1) ohm, clean and/or tighten the antenna base to fender
mounting hardware.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and
Repair > Antenna Extension Cable
Antenna: Service and Repair Antenna Extension Cable
REMOVAL
1. Remove glove box.
Antenna Cable
2. Disconnect extension cable end from antenna cable end. 3. Disconnect cable hanger clip from
HVAC unit. 4. Remove radio as necessary to gain access to extension cable. 5. Disconnect
extension cable from back of radio. 6. Remove extension cable from vehicle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and
Repair > Antenna Extension Cable > Page 7592
Antenna: Service and Repair Antenna Mast and Cable Lead
REMOVAL
1. Remove glove box from instrument panel.
Antenna Cable
2. Disconnect antenna cable connector from extension cable. 3. Remove right kick trim panel. 4.
Disengage rubber grommet insulator from door hinge pillar. 5. Pull antenna cable through hinge
pillar into open between door hinges. 6. Hoist and support vehicle on safety stands. 7. Remove
front wheel. 8. Remove front wheelhouse splash shield.
Antenna Mast
9. Slide the plastic sleeve up on antenna mast for access to mast. Remove antenna mast from
antenna base.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antenna > Component Information > Service and
Repair > Antenna Extension Cable > Page 7593
Antenna Cap Nut Remove/Install - Typical
10. Remove plastic cap from the cap nut. Using cap nut tool, remove cap nut holding antenna base
to front fender. 11. Remove antenna base from under front fender.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch
(For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch
Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch
REMOVAL
1. Open the front door.
Front Door Ajar Switch
2. Remove the screw holding the door ajar switch to the door B-pillar. 3
Remove the door ajar switch from the B-pillar.
4. Disconnect the wire connector from the back of the ajar switch and remove the switch.
INSTALLATION
- For installation, reverse the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Door Sensor/Switch
(For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS Trigger) Switch > Page 7599
Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch
REMOVAL
1. Release the sliding door latch and allow back of the door to pop open.
Sliding Door Ajar Switch
2. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar
switch from quarter panel opening. 3. Disconnect the wire connector from the back of the ajar
switch. 4. Remove the sliding door ajar switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Hood Sensor/Switch
(For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger
switch from top of the radiator closure panel.
Hood Ajar Switch
3. Disconnect the trigger switch from the wire connector and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Locations > Page 7607
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Locations > Page 7608
Keyless Entry Module: Adjustments
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30
seconds or when ignition switch is turned OFF, the
RKE module will end the programming mode. A single chime will sound to verify that the RKE
module will no longer receive additional Vehicle Access Code(s).
7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each
key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Module > Component Information > Locations > Page 7609
Keyless Entry Module: Service and Repair
REMOVAL
1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel.
RKE Module
3. Disconnect wire connector from RKE module. 4. Remove the RKE module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins >
Customer Interest for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery
Failure
Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely
MODELS:
1997 - 1998 (AB) Ram Van/Wagon
1997 - 1998 (AN) Dakota/Dakota Cab & Chassis
1998 (BRIBE)Ram Truck
1998 (DN) Durango
1997 (LH) Concorde/Intrepid/LHS/Vision
1997 - 1998 (NS) Town & Country/Caravan/Voyager
1997 - 1998 (PL) Neon
1997 (PR) Prowler
1997 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX).
SYMPTOM/CONDITION:
Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH
0815XX, perform the Repair Procedure.
PARTS REQUIRED:
AR 04686366 Transmitter, RKE- NS, PL & PR
AR 04759136AB Transmitter, RKE- LH
AR 56007049 Transmitter, RKE- AB & 1997 AN
AR 56008761 Transmitter 1, RKE- ZJ & DN
AR 56008762 Transmitter 2, RKE- ZJ
AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitter(s).
1. Replace RKE transmitter(s) that have discharged batteries.
2. Program the RKE transmitter(s) to the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-28-93 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Keyless Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature
Battery Failure
Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature
Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely
MODELS:
1997 - 1998 (AB) Ram Van/Wagon
1997 - 1998 (AN) Dakota/Dakota Cab & Chassis
1998 (BRIBE)Ram Truck
1998 (DN) Durango
1997 (LH) Concorde/Intrepid/LHS/Vision
1997 - 1998 (NS) Town & Country/Caravan/Voyager
1997 - 1998 (PL) Neon
1997 (PR) Prowler
1997 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX).
SYMPTOM/CONDITION:
Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH
0815XX, perform the Repair Procedure.
PARTS REQUIRED:
AR 04686366 Transmitter, RKE- NS, PL & PR
AR 04759136AB Transmitter, RKE- LH
AR 56007049 Transmitter, RKE- AB & 1997 AN
AR 56008761 Transmitter 1, RKE- ZJ & DN
AR 56008762 Transmitter 2, RKE- ZJ
AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitter(s).
1. Replace RKE transmitter(s) that have discharged batteries.
2. Program the RKE transmitter(s) to the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-28-93 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Keyless Entry >
Keyless Entry Transmitter > Keyless Entry Transmitter Battery > Component Information > Technical Service Bulletins >
Page 7624
Keyless Entry Transmitter Battery: Application and ID
The batteries can be removed without special tools and are readily available at local retail stores.
The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary.
Hands must be clean and dry.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
Component Information > Service and Repair > Door Lock Cylinder Switch
Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch
REMOVAL
1. Remove the door trim and water shield. 2. Close the door window. 3. Disconnect the door lock
cylinder switch wire connector from the door harness and wiring clip from the impact beam. 4.
Remove the outer handle from the door.
Door Lock Cylinder Switch
5. Disengage the lock tab holding switch to the back of the lock cylinder. 6. Remove the switch
from the door handle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Lock Cylinder Switch >
Component Information > Service and Repair > Door Lock Cylinder Switch > Page 7629
Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch
REMOVAL
1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside
latch release handle.
Liftgate Cylinder Lock Switch
4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch
REMOVAL
1. Remove the liftgate latch from the vehicle. 2. Disconnect the wire connector from the liftgate ajar
switch.
Liftgate Ajar Switch
3. Remove the screw holding the ajar switch to the liftgate latch and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Antitheft and Alarm Systems > Trunk/Liftgate
Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar (VTSS Trigger) Switch > Page
7634
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Lock Cylinder Switch
REMOVAL
1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside
latch release handle.
Liftgate Cylinder Lock Switch
4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations
Technical Service Bulletin # 08-23-99 Date: 990709
Radio Communication Equipment - Recommendations
NUMBER: 08-23-99
GROUP: Electrical
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17,
1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000
MODEL YEAR VEHICLES.
SUBJECT: Installation of Radio Transmitting Equipment
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram
Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth
Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000**
(DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ)
Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New
Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ)
Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand
Cherokee/Grand Wagoneer
DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment
Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in
properly installing communication equipment in DaimlerChrysler vehicles. This information should
be given to any owner inquiring about installing radio-transmitting equipment.
Installation Recommendations
DaimlerChrysler
Radio Communication Equipment Installation Recommendations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations > Page 7639
The following is excerpted from the owners manual of new DaimlerChrysler products:
"INSTALLATION OF RADIO TRANSMITTING EQUIPMENT
Special design considerations are incorporated into this vehicle's electronic system to provide
immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be
installed properly by trained personnel. The following must be observed during installation.
The positive power connection should be made directly to the battery and fused as close to the
battery as possible. The negative power connection should be made to body sheet metal adjacent
to the negative battery connection. This connection should not be fused.
Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care
should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or
operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring when
possible. Use only fully shielded coaxial cable.
Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mobile radio equipment with output power greater than normal may require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for
detailed assistance."
The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied
with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the
problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles,
the following information is provided. Always use good construction practices (see The ARRL
Handbook or other standard reference works).
The information contained in this guide has been prepared for use by persons installing two-way
radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with
current engineering principles and generally accepted practices, using the best information
available at the time of publication. It is not possible to cover all of the possible installations of
two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held
responsible for incidental or consequent damages arising out of the use of the information
contained herein. The responsibility for installations and modifications is the sole responsibility of
the customer.
The installation recommendations presented here are intended to supplement the radio
manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and
brake control before extensive driving.
1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan,
put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are
available at most body shops for this purpose.) This will keep moisture out of the carpet and
insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and
behind instrument panel.
If you mount the radio under the instrument panel, be sure that there is no interference with proper
operation of the foot controls. Mount the control head or front panel (especially the microphone
cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit
is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and
energy absorbing materials in the knee blocker (the lower part of the Instrument Panel).
For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power
relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed.
Try the installation out before you start drilling holes.
2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery
NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.:
radio presets) after a protracted time without battery power.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations > Page 7640
For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or
cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat
shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +)
lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle
has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder
and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard
corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and
the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola
Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG
cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi
Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with
cover 12033731 for standard SAE plastic fuses.
Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher
underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas.
Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest
location.
DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply
current would be conducted by an alternate current return path, which could cause the feedline to
overheat, with possible resulting damage.
For low or medium power installations, connect the ground (battery -) to body sheet near the power
feed point. If you use a screw through the floor, put body sealer over the underbody projection.
(Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high
power installations, connect the ground (battery -) lead at the battery connection to the body. This
is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse
or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so
diameter area of body panel where the ground lead is to be connected (usually the case with
commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or
5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size
for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the
terminal and the screw head. As above, some grease or protectant should be used if the
connection is in an unprotected area.
If the power cable must pass through the dash panel, try to find an existing hole with a grommet
that is unused. If none is available, pull the carpet back from under the dash panel in the passenger
footwell in the cabin. Locate a place where there are no other components on either side, as high
up as possible. An awl is the best tool to use to punch a small hole through to the engine
compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is
not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will
leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or
commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the
underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold,
steering shaft, throttle linkage, fans, etc. Tie wrap as required.
3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets
the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats
or carpet and padding. For most left hand drive vehicles, use the right side for best separation to
the main body harness (usually on the left side).
Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.
4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to
remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is
usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the
front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear
compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping
points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which
must be pierced to pass the cable.
Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie
wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back
and cushion, taking care that the cable is not pinched by the seat cushion when there is someone
sitting in the seat. On some vehicles, there may be a channel for wiring at this location.
For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a
good method to mount the transceiver to the shelf. It provides a good mounting surface, some
shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of
the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be
mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic
modules located in the rear of the vehicle.
In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22
watts (@70% efficiency). Do not pile things on top of the unit.
5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way
as the control and power cables. Route flat along body sheet metal wherever possible to avoid
sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some
cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is
important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is
not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at
UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits.
Do not rely on the obsolete military "RG" designations as an indicator of quality.
Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the
correct connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Cellular Phone > Component Information > Technical
Service Bulletins > Radio Communication Equipment - Recommendations > Page 7641
The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A
small amount of silicone dielectric grease (not the white heat sink compound) in the connector
(after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize
losses.
6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile
installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the
center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas
should be mounted at the very top edge of the clear portion of the glass away from the heater grid.
Vehicles with printed-on-glass antennas may be damaged by through-glass installations.
For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are
an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel
for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for
corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A
small grinder with a coarse stone will break through the anodized coating for electrical connection.
7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass
or body-lip mounts for anything other than for low power or temporary installations. Most of these
alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from
the feedline inside the passenger compartment, and may be picked up by the vehicle wiring.
For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short,
wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and
even some FM installations, the hood must be bonded to the body. In some cases the doors may
need to be bonded, as well.
Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass
(Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper)
require a half-wavelength antenna or a ground plane with radius approximately equal to the length
of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used.
Install on the inside of the body panel with a good adhesive or tape and provide a good RF
connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used.
Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay
one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof
mechanism for interference to the base and to the feedline.
For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center
conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in
antenna selection and is the best choice for electrical and mechanical considerations. Use the
proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with
power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the
antenna base.
To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where
the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or
plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through,
leaving 6 in., which can be taped, to the transmission line (easier without the connector, but
possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the
hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps
maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small
amount of silicone grease to the contact and insulator surface of the base. This will help exclude
water, but must be renewed periodically. Tip: if you remove your antenna to go through the car
wash, there are caps available to exclude water during the process.
In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If
necessary, the technique used on the roof can also be used to snake the cable down the inside the
pillar.
Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a
clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are
a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely
important.
Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler
Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations
Technical Service Bulletin # 08-23-99 Date: 990709
Radio Communication Equipment - Recommendations
NUMBER: 08-23-99
GROUP: Electrical
DATE: Jul. 9, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-16-98, DATED APRIL 17,
1998, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN THE 1998
TECHNICAL SERVICE BULLETIN MANUAL (PUBLICATION NO.81-699-99003). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE THE ADDITION OF THE 2000
MODEL YEAR VEHICLES.
SUBJECT: Installation of Radio Transmitting Equipment
MODELS: 1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan 1989 - **2000** (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon 1989 - 1993 (AD) Ram
Pickup/Ramcharger 1989 - 1993 (AG) Daytona 1989 - 1995 (AJ) LeBaron Coupe/LeBaron
Convertible 1989 - **2000** (AN) Dakota 1989 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager 1990 - 1993 (AY) Imperial/New Yorker Fifth
Avenue 1988 - 1992 (BB) Monaco/Premier 1994 - **2000** (BR/BE) Ram Pickup 1998 - **2000**
(DN) Durango 1992 - 1995 (ES) Chrysler Voyager (European Market) 1995 - **2000** (FJ)
Sebring/Avenger/Talon 1996 - **2000** (GS) Chrysler Voyager (International Market) 1995 **2000** (JA) Cirrus/Stratus/Breeze 1993 - **2000** (LH) Concorde/Intrepid/Vision/LHS/New
Yorker 1989 - 1992 (MJ) Comanche 1996 - **2000** (NS) Town & Country/Caravan/Voyager 1995 **2000** (PL) Neon 1992 - **2000** (SR) Viper/Viper GTS 1997 - **2000** (TJ) Wrangler 1999 **2000** (WJ) Grand Cherokee 1989 - **2000** (XJ) Cherokee/Wagoneer 1989 - 1995 (YJ)
Wrangler 1996 - 1998 (ZG) Grand Cherokee (International Market) 1993 - 1998 (ZJ) Grand
Cherokee/Grand Wagoneer
DISCUSSION: Included is a copy of DaimlerChrysler's Radio Communication Equipment
Installation Recommendations. It is being provided with this Technical Service Bulletin to assist in
properly installing communication equipment in DaimlerChrysler vehicles. This information should
be given to any owner inquiring about installing radio-transmitting equipment.
Installation Recommendations
DaimlerChrysler
Radio Communication Equipment Installation Recommendations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7646
The following is excerpted from the owners manual of new DaimlerChrysler products:
"INSTALLATION OF RADIO TRANSMITTING EQUIPMENT
Special design considerations are incorporated into this vehicle's electronic system to provide
immunity to radio frequency signals. Mobile two-way radio and telephone equipment must be
installed properly by trained personnel. The following must be observed during installation.
The positive power connection should be made directly to the battery and fused as close to the
battery as possible. The negative power connection should be made to body sheet metal adjacent
to the negative battery connection. This connection should not be fused.
Antennas for two-way radios should be mounted on the roof or the rear area of the vehicle. Care
should be used in mounting antennas with magnet bases. Magnets may affect the accuracy or
operation of the compass on vehicles so equipped.
The antenna cable should be as short as practical and routed away from the vehicle wiring when
possible. Use only fully shielded coaxial cable.
Carefully match the antenna and cable to the radio to ensure a low Standing Wave Ratio (SWR).
Mobile radio equipment with output power greater than normal may require special precautions.
All installations should be checked for possible interference between the communications
equipment and the vehicle's electronic systems. A Technical Service Bulletin (TSB) is available for
detailed assistance."
The owner's first line of contact regarding vehicle problems is the dealer. The literature supplied
with each vehicle lists the steps to be taken in the event the dealer is unable to resolve the
problem. To assist in properly installing communications equipment in DaimlerChrysler vehicles,
the following information is provided. Always use good construction practices (see The ARRL
Handbook or other standard reference works).
The information contained in this guide has been prepared for use by persons installing two-way
radio equipment (transmitters and receivers) in vehicles. It has been prepared in accordance with
current engineering principles and generally accepted practices, using the best information
available at the time of publication. It is not possible to cover all of the possible installations of
two-way radio equipment in this guide. Accordingly, DaimlerChrysler Corporation cannot be held
responsible for incidental or consequent damages arising out of the use of the information
contained herein. The responsibility for installations and modifications is the sole responsibility of
the customer.
The installation recommendations presented here are intended to supplement the radio
manufacturer's instructions. Test the entire installation for anomalies, especially drivetrain and
brake control before extensive driving.
1. CONTROLS Mount the transceiver to a solid surface. If you use screws through the floor pan,
put body sealer over the underbody projections. (Stamped acorn nuts, filled with sealer are
available at most body shops for this purpose.) This will keep moisture out of the carpet and
insulation, and will forestall rust in this area. Watch out for wire harnesses routed under carpet and
behind instrument panel.
If you mount the radio under the instrument panel, be sure that there is no interference with proper
operation of the foot controls. Mount the control head or front panel (especially the microphone
cable) so that it is clear of the steering wheel and column controls and passenger airbag. If the unit
is heavy, extra bracing may be needed for stability. Newer vehicles have more structure and
energy absorbing materials in the knee blocker (the lower part of the Instrument Panel).
For one-piece transceivers, if ignition switch control is desired, it is good practice to use a power
relay to avoid overloading the ignition switch, and to maintain the advantages of direct battery feed.
Try the installation out before you start drilling holes.
2. POWER WIRING To reduce the hazard of working on the vehicle, disconnect the battery
NEGATIVE before beginning work. Note that some components may lose short-term memory (e.g.:
radio presets) after a protracted time without battery power.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7647
For low or medium power transmitters (up to 55W FM or 110W SSB or CW), the power outlet or
cigar lighter feed may be used. Use a 1/4" jumper terminal at the socket or splice (solder and heat
shrink or tape). For higher power transmitters, including amplifiers, connect the power (battery +)
lead at the battery or at the power distribution center or at the positive jump-start post, if the vehicle
has one. An appropriate terminal should be used. If the terminal is exposed to the weather, solder
and apply a commercial protectant (wheel bearing grease is an acceptable alternative.) to retard
corrosion. This lead should be fused as close to the battery as practical to protect the wiring (and
the vehicle)! If the power connection is underhood, use a weatherproof fuse holder. Motorola
Communications Division supplies a weatherproof holder, part number 09-84277B01 for 5AG
cartridge fuses that is part of their standard installation kit. Packard Electric Division of Delphi
Automotive Systems makes an insulator, part number 12033769, terminal number 12020156 with
cover 12033731 for standard SAE plastic fuses.
Vinyl-insulated wire, typically supplied with transceivers is not entirely suitable for the higher
underhood temperatures in modern vehicles. Route underhood wiring away from all hot areas.
Body sheet metal, away from the exhaust, radiator, A/C liquid line and engine is usually the coolest
location.
DO NOT FUSE THE GROUND LEAD. If the ground-side fuse were to open, the entire supply
current would be conducted by an alternate current return path, which could cause the feedline to
overheat, with possible resulting damage.
For low or medium power installations, connect the ground (battery -) to body sheet near the power
feed point. If you use a screw through the floor, put body sealer over the underbody projection.
(Stamped acorn nuts, filled with sealer are available at most body shops for this purpose.) For high
power installations, connect the ground (battery -) lead at the battery connection to the body. This
is usually a 6 or 8 AWG black wire from the battery negative terminal to a screw at the wheelhouse
or radiator support. If a separate sheet metal ground is used, clean the paint off a one inch or so
diameter area of body panel where the ground lead is to be connected (usually the case with
commercial trunk mount radios). An awl is the best tool to use to pierce a starting hole for a #12 or
5mm, minimum plated ground screw. A ring terminal with lockwasher serrations of the proper size
for the screw or a separate serrated (not a split or SAE) lockwasher should be used between the
terminal and the screw head. As above, some grease or protectant should be used if the
connection is in an unprotected area.
If the power cable must pass through the dash panel, try to find an existing hole with a grommet
that is unused. If none is available, pull the carpet back from under the dash panel in the passenger
footwell in the cabin. Locate a place where there are no other components on either side, as high
up as possible. An awl is the best tool to use to punch a small hole through to the engine
compartment. If the position is good, enlarge the hole by driving the awl in up to the shank. If this is
not large enough to easily pass the cable, enlarge it by using a larger tapered punch. This will
leave an extruded hole with no sharp edges. Install the cable and seal the hole with silicone RTV or
commercial body sealer on both sides. Seal any extra holes that you may have made. Dress the
underhood wiring so that it is sate from all hazards, which include the following: exhaust manifold,
steering shaft, throttle linkage, fans, etc. Tie wrap as required.
3. CABLING Route control cables under the floor mats, inside the corner where the floor pan meets
the rocker panel for best protection. Remove the sill plates and tuck the cable under the floor mats
or carpet and padding. For most left hand drive vehicles, use the right side for best separation to
the main body harness (usually on the left side).
Route the cable along the extreme outboard edge of the floor pan, under the side trim, if possible.
4. REMOTE TRANSCEIVER For trunk mount installations in passenger cars, you may need to
remove the rear seat cushion and seat back to get the cable into the trunk. The seat cushion is
usually clipped at the front, lower edge by its own frame: push down and back, then lift. Note the
front and rear clipping points for ease of reinstallation. The seat back is usually clipped to the rear
compartment inner panel: pull out at the bottom and slide up to remove. Again, note the clipping
points for ease of reinstallation. There is usually a vapor/sound barrier behind the seat back, which
must be pierced to pass the cable.
Open the trunk and pick a spot where the cable is safe from chafing on any sharp sheet metal. Tie
wrap or tape in place at this location. Repair the barrier sheet if necessary. Replace the seat back
and cushion, taking care that the cable is not pinched by the seat cushion when there is someone
sitting in the seat. On some vehicles, there may be a channel for wiring at this location.
For remote control radios, a sheet of 1/2 in. plywood one or two inches larger than the radio, is a
good method to mount the transceiver to the shelf. It provides a good mounting surface, some
shock and vibration isolation, and it keeps moisture away from the radio. Mounting on the floor of
the trunk is not recommended. To conserve trunk space, in some vehicles, the radio may be
mounted to the rear compartment panel. Locate as far as possible from any vehicle electronic
modules located in the rear of the vehicle.
In any case, provide good air circulation; a 50 watt RF output FM transmitter will dissipate about 22
watts (@70% efficiency). Do not pile things on top of the unit.
5. TRANSMISSION LINE The transmission line (coaxial cable) should be treated in the same way
as the control and power cables. Route flat along body sheet metal wherever possible to avoid
sharp edges and pinches. If it is necessary to cross over wiring, cross at right angles. In some
cases, additional shielding between the transmission line and the vehicle wiring may be helpful. It is
important to maintain the maximum spacing from the vehicle harnesses, especially if the antenna is
not a good match. Use the best cable available (98-99% braid coverage or braid/foil) especially at
UHF and above. Mechanical pressure on the cable can cause degradation or even short circuits.
Do not rely on the obsolete military "RG" designations as an indicator of quality.
Cut off, do not coil excess transmission line (This forms a choke balun.) and terminate in the
correct connector.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Citizens Band Radio (CB) > Component Information >
Technical Service Bulletins > Radio Communication Equipment - Recommendations > Page 7648
The use of N, BNC or C connectors is recommended over "UHF" (PL-259/S0-239) connectors. A
small amount of silicone dielectric grease (not the white heat sink compound) in the connector
(after soldering) will minimize condensation problems. Cut the line as short as practical, to minimize
losses.
6. ANTENNA LOCATION Antenna location is the most important consideration in any mobile
installation. For VHF and UHF antennas the recommended place on almost all vehicles is in the
center of the roof. The center of the deck lid is an acceptable alternate. Glass-mounted antennas
should be mounted at the very top edge of the clear portion of the glass away from the heater grid.
Vehicles with printed-on-glass antennas may be damaged by through-glass installations.
For HF antennas, refer to the manufacturer's instructions and follow them closely, unless you are
an accomplished antenna experimenter. HF antennas should be mounted to body or frame steel
for a good counterpoise as well as structural strength. Aluminum bumpers are heavily anodized for
corrosion protection, and the coating (aluminum oxide) is very hard as well as nonconductive. A
small grinder with a coarse stone will break through the anodized coating for electrical connection.
7. ANTENNA INSTALLATION Permanently installed antennas are preferable over magnetic, glass
or body-lip mounts for anything other than for low power or temporary installations. Most of these
alternate antennas will reflect some power back at the feedpoint. Much of this will be radiated from
the feedline inside the passenger compartment, and may be picked up by the vehicle wiring.
For deck lid installations, the deck lid must be bonded to the body, across the hinges, with short,
wide tinned braid straps. They must connect to clean sheet metal at both ends. For AM/SSB and
even some FM installations, the hood must be bonded to the body. In some cases the doors may
need to be bonded, as well.
Glass-mount antennas will not work or will only work very poorly in vehicles with metallized glass
(Electrically-heated windshields or some solar reflective glass). Non-metallic bodies (e.g., Viper)
require a half-wavelength antenna or a ground plane with radius approximately equal to the length
of a quarter-wave antenna. Copper is the best choice, but aluminum or even steel may be used.
Install on the inside of the body panel with a good adhesive or tape and provide a good RF
connection to the coax shield at the feedpoint. Screen, mesh or thin sheet stock may be used.
Shape is not critical, but some directional characteristics may be noted if it is not round. Try to stay
one-quarter wavelength away from edges, including sunroof openings. Consider the sunroof
mechanism for interference to the base and to the feedline.
For VHF and UHF, a good quality "NMO" (New Motorola) base or other mount with feedline (center
conductor and shield) soldered to base is recommended. This will allow the maximum flexibility in
antenna selection and is the best choice for electrical and mechanical considerations. Use the
proper hole saw (3/4 in. for NMO) or have it done professionally if you are not comfortable with
power tools. Hole plugs are available, for use at sale or trade-in, if you expect to remove the
antenna base.
To install the antenna base in the hole, remove the one or two-door trim pieces at the pillar where
the cable is to be routed and ease the headliner away from the roof. Insert a piece of flat steel or
plastic banding (1/2 in. to 3/4 in. wide) and guide to the desired corner. Pull the banding through,
leaving 6 in., which can be taped, to the transmission line (easier without the connector, but
possible even with a PL-259). Continue pulling until the antenna base is one inch or less from the
hole, then seat the base and screw on the outside ring, 0-ring down. A little silicone grease helps
maintain a good seal for the life of the vehicle. Tighten with an open-end wrench, and apply a small
amount of silicone grease to the contact and insulator surface of the base. This will help exclude
water, but must be renewed periodically. Tip: if you remove your antenna to go through the car
wash, there are caps available to exclude water during the process.
In most vehicles, RG-58-sized cable will fit between the pillar trim and body sheet metal. If
necessary, the technique used on the roof can also be used to snake the cable down the inside the
pillar.
Install the connector very carefully. There are good instructions in The ARRL Handbook. Use a
clean, hot, high-wattage iron and work quickly, to prevent damage to the cable dielectric. If you are
a beginner or are not comfortable with this kind of detail work, ask for help. It is extremely
important.
Electrical/Electronic Systems Compatibility Department CIMS 481-47-20 DaimlerChrysler
Corporation 800 Chrysler Drive East Auburn Hills, MI 48326-2757
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7653
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7654
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7655
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7656
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7657
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7658
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7659
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7660
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7661
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7662
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7663
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7664
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7665
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7666
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7667
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7668
Driver/Vehicle Information Display: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7669
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7670
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7671
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7672
Driver/Vehicle Information Display: Electrical Diagrams
Information Center
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7673
Message Center (Part 1 Of 4)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7674
Message Center (Part 2 Of 4)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7675
Message Center (Part 3 Of 4)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Diagrams > Diagram Information and Instructions > Page 7676
Message Center (Part 4 Of 4)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Message Center
Driver/Vehicle Information Display: Service and Repair Message Center
REMOVAL
1. Remove A-pillar trim. 2. Remove instrument panel top cover. Refer to instrument panel top cover
removal procedures. 3. Disconnect the wire connector from back of message center. 4. Remove
screws holding message center to instrument panel top cover. 5. Remove message center from
instrument panel top cover.
INSTALLATION
1. Place message center in position on top cover. 2. Install screws to hold message center to
instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install
instrument panel top cover. 5. Install A-pillar trim.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Driver/Vehicle Information Display > Component
Information > Service and Repair > Message Center > Page 7679
Driver/Vehicle Information Display: Service and Repair Message Center Lamp
REMOVAL
1. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Removal procedures.
Message Center Lamp Location
2. Locate the lamp in question. 3. Remove lamp and check lamp. If lamp is good test the power
supply to the lamp.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Description and Operation
Seat Memory Switch: Description and Operation
SYSTEM OPERATION
Memory Selector Switches The memory selector switches are mounted on the driver's door trim
panel within easy reach of the driver. They provide a means to set or recall either of two positions
of seat and recliner, and the side view mirrors as chosen by the driver.
The inputs from these switches to the memory seat/mirror module is a ground level signal. 1.
Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and
release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press
any switches for 10 seconds. 4. To program the second driver's position, follow the above
sequence. 5. To recall either of the programmed positions momentarily press and release either
memory selector switch 1 or 2.
Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing
requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum
hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must
be met for proper operation of the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Description and Operation > Page 7684
Seat Memory Switch: Testing and Inspection
To test the memory selector switch:
1. Remove the memory selector switch. Refer to removal procedure.
Memory Selector Switch Continuity
2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Memory Positioning Systems > Seat Memory Switch >
Component Information > Description and Operation > Page 7685
Seat Memory Switch: Service and Repair
REMOVAL
1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel.
2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Compact Disc
Player (CD) > Component Information > Service and Repair
Compact Disc Player (CD): Service and Repair
REMOVAL
1. Remove HVAC switch bezel.
Radio
2. Remove screws holding radio to instrument panel.
Radio Connectors
3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back
of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from
back of radio. 7. Remove radio from vehicle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise
Radio/Stereo Noise Filter: Customer Interest Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7699
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7700
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7701
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Customer Interest for Radio/Stereo
Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7702
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise
Radio/Stereo Noise Filter: All Technical Service Bulletins Radio - Poor AM Reception/Ignition Noise
NUMBER: 08-45-99
GROUP: Electrical
DATE: Dec. 31, 1999
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-03-96 DATED FEB 2,
1996, AND NOTED IN THE 1996 SERVICE BULLETIN MANUAL (PUBLICATION NO.
81-699-97010). THIS IS A COMPLETE REVISION AND NO **ASTERISKS** ARE USED TO
HIGHLIGHT THE CHANGES.
SUBJECT: AM Radio Reception
OVERVIEW: This bulletin involves attaching a shield and a capacitor to the ignition coil module,
adding a jumper harness, ground strap and tie-strap.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 3.3L OR 3.8L ENGINE.
SYMPTOM/CONDITION: Vehicle operator complaint of poor AM radio reception due to ignition
noise (static that varies with engine RPM) on low power/distant stations.
DIAGNOSIS: If the vehicle operator describes the condition, tune in a weaker station. If static that
varies with engine RPM is heard check the antenna connection, the antenna ground, the ground
straps across the right side motor mount, and from the back of the engine to the dash panel. If
these check ok but the static condition still exists, perform the Repair Procedure.
PARTS REQUIRED:
1 05016107AA Shield Package
Contents Of Shield Package:
1-Suppression Shield, 2-Attaching Stud Assemblies, 2-Attaching Nuts
1 05016105AA Wiring Repair Package 1996-1998
1 05016106AA Wiring Repair Package 1999-2000
Contents of Wiring Packages:
1-Wiring Jumper, 1-Wiring Tie-Strap, 1-Ground Strap, 1-Ignition Noise Suppression Capacitor,
1-Capacitor Mounting Bolt
REPAIR PROCEDURE:
1. Disconnect the negative battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7708
Fig. 1
2. Disconnect the electrical connector from the ignition coil module, Figure 1.
3. Remove the ignition coil module bottom-forward mounting bolt and discard.
Fig. 2
4. Attach the supplied capacitor to the ignition coil module with the supplied bolt, Figure 2. Torque
the screw to 10-15 Nm (85-125 in. lbs.)
5. Connect the single wire connector of the jumper harness to the suppression capacitor. Then
connect the jumper harness between the ignition coil module and the powertrain harness
connector, Figure 2.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7709
Fig. 3
Fig. 3A
6. With the supplied tie-strap, tie back the extra length of the jumper harness to the main bundle of
the powertrain harness (see fig. 3 or fig. 3a).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7710
Fig. 4
7. Remove and discard the two top bolts that mount the ignition coil module, Figure 4.
8. Replace the discarded ignition coil module mounting bolts with the supplied double-ended studs.
Torque studs to 10-15 Nm (85-125 in. lbs.)
Fig. 5
9. Install the shield over the double-ended studs and attach with two nuts from the shield kit, Figure
5. Torque the nuts to 10-15 Nm (85-125 in. lbs.).
10. Turn the ignition switch to the Unlock position so the steering wheel can rotate.
11. Raise vehicle. Then turn the front wheels to the left.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > All Technical Service Bulletins for
Radio/Stereo Noise Filter: > 08-45-99 > Dec > 99 > Radio - Poor AM Reception/Ignition Noise > Page 7711
Fig. 6
12. Attach the ground strap from the wiring package (using the existing fasteners) to the right strut
assembly and the wheelhouse panel. Flattening out the anti-rotation tabs of the ground strap
eyelets (if so equipped) may be helpful. Tighten the ground strap terminal and bracket attaching
bolt on the strut assembly to 13.5 Nm (120 in. lbs.), tighten the attaching bolt to the wheelhouse
panel/frame to 11 Nm (95 in. lbs.), Figure 6.
13. Center the front wheels and lower the vehicle.
14. Connect the negative battery cable and set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
08-12-02-91 0.4 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Radio/Stereo Noise Filter > Component Information > Technical Service Bulletins > Page 7712
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Description and Operation
Remote Switch: Description and Operation
SYSTEM OPERATION
Remote Radio Switch Operational View
A remote radio control switch option is available on LXI models sold in North America with the
AM/FM/ cassette/S-band graphic equalizer with CD changer control feature (RBN sales code), or
the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two
rocker-type switches are mounted on the back (instrument panel side) of the steering wheel
spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset
station advance functions. The switch on the right spoke is the volume control switch and has
volume up, and volume down functions.
These switches are resistor multiplexed units that are hard-wired to the Body Control Module
(BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision
Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended.
For more information on the operation of the remote radio switch controls, refer to the owner's
manual in the vehicle glove box.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7716
Remote Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the
steering wheel.
Remote Radio Switches
Remote Radio Switches Test
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right (Left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check
for continuity between the ground circuit cavity of the switch wire harness connector and a good
ground. There should be continuity If OK,
go to Step 6. If not OK, repair the open circuit as required.
6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check
for continuity between the radio control circuit
cavity of the remote radio switch wire harness connector and a good ground. There should be no
continuity. If OK, go to Step 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the BCM wire harness
connector. There should be continuity. If OK, refer to the Powertrain Management/Computer and
Control Systems/proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK,
repair the open circuit as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Radio/Stereo >
Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7717
Remote Switch: Service and Repair
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag
system capacitor to discharge before further service. 2. From the underside of the steering wheel,
remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the
airbag module away from the steering wheel far enough to access the wire harness connectors on
the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness
connectors from the back of the airbag module. 5. Remove the driver side airbag module from the
vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness
connector from the remote radio switch (s). 8. Remove three screws securing steering wheel rear
cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side
of switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed and driver in drivers
seat.
INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be
careful to index them correctly before pressing them into place.
- Tighten the airbag module mounting screws to 10.2 N.m (90 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams
Speaker: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 7721
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Diagrams > Page 7722
Speaker: Description and Operation
SYSTEM OPERATION
Name Brand Speaker Relay Relay is located in the junction block. To test relay refer to the Audio
Diagnostic Test Procedures or use a known good relay.
Choke Location
Choke-Infinity Speakers If the audio system is lacking bass response, check for continuity across
the choke connector. If no continuity Replace choke. The choke is located on the bracket behind
the junction block/body control module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker
Speaker: Service and Repair D-Pillar Speaker
REMOVAL
1. Remove D-pillar trim panel as necessary to gain access to door speaker. 2. Disconnect wire
connector from speaker.
D-Pillar Speaker
3. Remove by sliding speaker out of bracket by pushing on magnet. The capacitor is wrapped with
foam tape. 4. Remove speaker.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker > Page 7725
Speaker: Service and Repair Front Door Speaker
REMOVAL
1. Remove front door trim panel as necessary to gain access to door speaker.
Front Door Speaker
2. Remove screws holding speaker to bracket. 3. Remove speaker from bracket. 4. Disconnect
wire connector from speaker. 5. Remove speaker.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker > Page 7726
Speaker: Service and Repair Instrument Panel Speaker
REMOVAL
1. Remove instrument panel top cover.
Left Instrument Panel Speaker
Right Instrument Panel Speaker
2. Remove screws holding speaker to instrument panel and remove speaker. 3. Remove anti
rocking finger screw. 4. Disconnect wire connector from speaker. 5. Remove speaker.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Speaker >
Component Information > Service and Repair > D-Pillar Speaker > Page 7727
Speaker: Service and Repair Quarter Panel Speaker
REMOVAL
1. Remove quarter trim bolster from quarter trim panel.
Quarter Panel Speaker
2. Remove screws holding speaker to inner quarter panel. 3. Separate speaker from quarter panel.
4. Disconnect wire connector from speaker. 5. Remove speaker.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Radio, Stereo, and Compact Disc > Tape Player >
Component Information > Service and Repair
Tape Player: Service and Repair
REMOVAL
1. Remove HVAC switch bezel.
Radio
2. Remove screws holding radio to instrument panel.
Radio Connectors
3. Pull radio rearward to gain access to back of radio. 4. Remove bolt holding ground strap to back
of radio. 5. Disconnect antenna cable from back of radio. 6. Disconnect the wire connectors from
back of radio. 7. Remove radio from vehicle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations > Page 7735
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations > Page 7736
Keyless Entry Module: Adjustments
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30
seconds or when ignition switch is turned OFF, the
RKE module will end the programming mode. A single chime will sound to verify that the RKE
module will no longer receive additional Vehicle Access Code(s).
7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each
key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Relays and Modules - Accessories and Optional
Equipment > Keyless Entry Module > Component Information > Locations > Page 7737
Keyless Entry Module: Service and Repair
REMOVAL
1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel.
RKE Module
3. Disconnect wire connector from RKE module. 4. Remove the RKE module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS
Trigger) Switch
Door Sensor/Switch (For Alarm): Service and Repair Front Door Ajar (VTSS Trigger) Switch
REMOVAL
1. Open the front door.
Front Door Ajar Switch
2. Remove the screw holding the door ajar switch to the door B-pillar. 3
Remove the door ajar switch from the B-pillar.
4. Disconnect the wire connector from the back of the ajar switch and remove the switch.
INSTALLATION
- For installation, reverse the above procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Door Sensor/Switch (For Alarm) > Component Information > Service and Repair > Front Door Ajar (VTSS
Trigger) Switch > Page 7743
Door Sensor/Switch (For Alarm): Service and Repair Sliding Door Ajar (VTSS Trigger) Switch
REMOVAL
1. Release the sliding door latch and allow back of the door to pop open.
Sliding Door Ajar Switch
2. Through opening at the rear edge of the sliding door on outside of the vehicle, pry door ajar
switch from quarter panel opening. 3. Disconnect the wire connector from the back of the ajar
switch. 4. Remove the sliding door ajar switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Hood Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger
switch from top of the radiator closure panel.
Hood Ajar Switch
3. Disconnect the trigger switch from the wire connector and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch
Lock Cylinder Switch: Service and Repair Door Lock Cylinder Switch
REMOVAL
1. Remove the door trim and water shield. 2. Close the door window. 3. Disconnect the door lock
cylinder switch wire connector from the door harness and wiring clip from the impact beam. 4.
Remove the outer handle from the door.
Door Lock Cylinder Switch
5. Disengage the lock tab holding switch to the back of the lock cylinder. 6. Remove the switch
from the door handle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Lock Cylinder Switch > Component Information > Service and Repair > Door Lock Cylinder Switch > Page
7751
Lock Cylinder Switch: Service and Repair Liftgate Lock Cylinder Switch
REMOVAL
1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside
latch release handle.
Liftgate Cylinder Lock Switch
4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation
Remote Switch: Description and Operation
SYSTEM OPERATION
Remote Radio Switch Operational View
A remote radio control switch option is available on LXI models sold in North America with the
AM/FM/ cassette/S-band graphic equalizer with CD changer control feature (RBN sales code), or
the AM/FM/CD/ cassette/3-band graphic equalizer (RAZ sales code) radio receivers. Two
rocker-type switches are mounted on the back (instrument panel side) of the steering wheel
spokes. The switch on the left spoke is the seek switch and has seek up, seek down, and preset
station advance functions. The switch on the right spoke is the volume control switch and has
volume up, and volume down functions.
These switches are resistor multiplexed units that are hard-wired to the Body Control Module
(BCM) through the clockspring. The BCM sends the proper messages on the Chrysler Collision
Detection (CCD) data bus network to the radio receiver. For diagnosis of the BCM or the CCD data
bus, the use of a DRB scan tool and the proper Diagnostic Procedures manual are recommended.
For more information on the operation of the remote radio switch controls, refer to the owner's
manual in the vehicle glove box.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7755
Remote Switch: Testing and Inspection
WARNING: ON VEHICLES EQUIPPED WITH AIR BAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIRBAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag system
capacitor to discharge before further service. 2. Remove the remote radio switch(es) from the
steering wheel.
Remote Radio Switches
Remote Radio Switches Test
3. Use an ohmmeter to check the switch resistance as shown in the Remote Radio Switch Test
table.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right (Left remote radio switch orientation is with the steering wheel installed, and driver in
drivers seat.
4. If the switch resistance checks OK, go to Step 5. If not OK, replace the faulty switch. 5. Check
for continuity between the ground circuit cavity of the switch wire harness connector and a good
ground. There should be continuity If OK,
go to Step 6. If not OK, repair the open circuit as required.
6. Unplug the 24-way white wire harness connector from the Body Control Module (BCM). Check
for continuity between the radio control circuit
cavity of the remote radio switch wire harness connector and a good ground. There should be no
continuity. If OK, go to Step 7. If not OK, repair the short circuit as required.
7. Check for continuity between the radio control circuit cavities of the remote radio switch wire
harness connector and the BCM wire harness
connector. There should be continuity. If OK, refer to the Powertrain Management/Computer and
Control Systems/proper Diagnostic Procedures to test the BCM and the CCD data bus. If not OK,
repair the open circuit as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Remote Switch, Audio - Stereo > Component Information > Description and Operation > Page 7756
Remote Switch: Service and Repair
WARNING: ON VEHICLES EQUIPPED WITH AIRBAGS, REFER TO AIR BAGS AND SEAT
BELTS/AIR BAGS BEFORE ATTEMPTING ANY STEERING WHEEL, STEERING COLUMN, OR
INSTRUMENT PANEL COMPONENT DIAGNOSIS OR SERVICE. FAILURE TO TAKE THE
PROPER PRECAUTIONS COULD RESULT IN ACCIDENTAL AIR-BAG DEPLOYMENT AND
POSSIBLE PERSONAL INJURY.
REMOVAL 1. Disconnect and isolate the battery negative cable. Wait two minutes for the airbag
system capacitor to discharge before further service. 2. From the underside of the steering wheel,
remove the (3) bolts that secure the driver side airbag module to the steering wheel. 3. Pull the
airbag module away from the steering wheel far enough to access the wire harness connectors on
the back of the airbag module. 4. Unplug the airbag module and horn switch wire harness
connectors from the back of the airbag module. 5. Remove the driver side airbag module from the
vehicle. 6. Remove the steering wheel from the steering column. 7. Unplug the wire harness
connector from the remote radio switch (s). 8. Remove three screws securing steering wheel rear
cover. 9. Remove the remote radio switch from the steering wheel by depressing tabs on each side
of switch.
NOTE: The right remote radio switch back is white in color. The left switch back is black in color.
The right/left remote radio switch orientation is with the steering wheel installed and driver in drivers
seat.
INSTALLATION For installation, reverse the above procedure. The switches can only be installed one way. Be
careful to index them correctly before pressing them into place.
- Tighten the airbag module mounting screws to 10.2 N.m (90 in. lbs.).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar
(VTSS Trigger) Switch
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Ajar (VTSS Trigger) Switch
REMOVAL
1. Remove the liftgate latch from the vehicle. 2. Disconnect the wire connector from the liftgate ajar
switch.
Liftgate Ajar Switch
3. Remove the screw holding the ajar switch to the liftgate latch and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Sensors and Switches - Accessories and Optional
Equipment > Trunk/Liftgate Sensor/Switch (For Alarm) > Component Information > Service and Repair > Liftgate Ajar
(VTSS Trigger) Switch > Page 7761
Trunk/Liftgate Sensor/Switch (For Alarm): Service and Repair Liftgate Lock Cylinder Switch
REMOVAL
1. Remove the inner trim panel from the liftgate 2. Disconnect the door lock cylinder switch wire
connector from the liftgate harness and clip from the liftgate inner panel. 3. Remove the outside
latch release handle.
Liftgate Cylinder Lock Switch
4. Disconnect the lock tab holding the switch to the back of lock cylinder and install the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7767
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7768
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7769
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7770
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7771
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7772
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7773
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7774
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7775
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7776
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7777
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7778
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7779
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7780
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7781
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7782
Trailer Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7783
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7784
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7785
Trailer Connector: Electrical Diagrams
Trailer Tow (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Towing / Trailer System > Trailer Connector >
Component Information > Diagrams > Diagram Information and Instructions > Page 7786
Trailer Tow (Part 2 Of 2)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions
Trailer Connector: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7791
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7792
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7793
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7794
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7795
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7796
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7797
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7798
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7799
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7800
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7801
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7802
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7803
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7804
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7805
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7806
Trailer Connector: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7807
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7808
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7809
Trailer Connector: Electrical Diagrams
Trailer Tow (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trailer Connector > Component Information >
Diagrams > Diagram Information and Instructions > Page 7810
Trailer Tow (Part 2 Of 2)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Description
and Operation
Trip Computer: Description and Operation
SYSTEM OPERATION
Compass Mini Trip Computer (CMTC) The Compass mini-trip computer (CMTC) system is located
in the overhead console. CMTC consists of an electronic control module with a vacuum fluorescent
display (VFD) and function switches. The CMTC consists of an electronic module that displays
compass, trip computer and temperature features. Actuating the STEP switch will cause the CMTC
to change mode of operation when the ignition is ON.
Examples: Compass/Temperature
- Trip odometer (ODO)
- Average miles per gallon (ECO)
- Instant miles per gallon (ECO)
- Distance to empty (DTE)
- Elapsed time (ET)
- Off
The CMTC module in the overhead console has three buttons used to select various functions. The
CMTC selector buttons will not operate until the ignition is in the RUN position.
When the ignition switch is first turned to the Run position the CMTC display: Blanks momentarily
- All segments of the VFD will light for one second
- Blanks momentarily
- Returns to the last mode setting selected before the ignition was last switched OFF.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and
Inspection > Testing
Trip Computer: Testing and Inspection Testing
The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on
many of its internal functions. CMTC diagnostics may be performed using a scan tool and the
proper Body Control Module Testing and Inspection Procedures or by using the following
procedure.
1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn
ignition switch to the ON position. The CMTC will perform internal checks while lighting all
segments of the vacuum florescent display.
Upon completion of the internal check the CMTC will display. PASS
- FAIL
- CCD
If any segment of the CMTC fails to light replace the module.
If FAIL is displayed replace the module.
If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper
operation. If the CCD bus and the BCM are OK, replace the CMTC module.
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Testing and
Inspection > Testing > Page 7816
Trip Computer: Testing and Inspection Traveler Messages
Traveler data is obtained from the Body Control Module (BCM) on the CCD bus wires. The CMTC
will not display information for any of the screens for which it did not receive the bus messages.
The label corresponding to the missing information will be lit. If no traveler data is displayed, check
the CCD communications and the BCM. If the brightness level is improper check the CCD bus.
One general method for checking the CCD bus communications between CMTC and the BCM is
refer to the following procedure.
1. STEP the CMTC to the Elapsed Time (ET). 2. Press and release the reset button to reset the
module. 3. If the elapsed time clock does not reset, or fails to update, check the CCD wires and the
BCM.
- A scan tool is recommended for checking the CCD and the BCM.
4. Perform the CMTC self diagnosis before replacing the module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and
Repair > Compass Mini-Trip Computer (CMTC) Module
Trip Computer: Service and Repair Compass Mini-Trip Computer (CMTC) Module
REMOVAL
1. Disconnect battery negative cable. 2. Remove overhead console.
Compass Mini-Trip Computer
3. Remove the six screws holding CMTC module to overhead console. 4. Remove CMTC module
from console.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Accessories and Optional Equipment > Trip Computer > Component Information > Service and
Repair > Compass Mini-Trip Computer (CMTC) Module > Page 7819
Trip Computer: Service and Repair Compass Mini-Trip Computer (CMTC) Lamp
REMOVAL
1. Remove overhead console.
CMTC Lamp Bulbs
2. Rotate bulb socket counterclockwise one quarter turn. 3. Pull bulb socket from CMTC module.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Technical Service Bulletins > BCM - Auto Lamp DTC Diagnostics
Body Control Module: Technical Service Bulletins BCM - Auto Lamp DTC Diagnostics
NO: 08-40-98
GROUP: Electrical
DATE: Sept. 25, 1998
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 08-40-97, DATED
DECEMBER 12, 1997, WHICH SHOULD BE REMOVED FROM YOUR FILES AND NOTED IN
THE 1997 SERVICE BULLETIN MANUAL (PUBLICATION NO. 81-699-98004). ALL REVISIONS
ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITION OF 1999 MODEL
VEHICLES.
MODELS: 1998 - **1999** (NS) Town & Country/Caravan/Voyager
DISCUSSION:
During service diagnostics, the Body Control Module (BCM) may indicate an Auto Headlamp
Sensor/Signal Circuit DTC. If this occurs, determine if the vehicle is equipped with auto head
lamps.
If the vehicle IS NOT equipped with auto headlamps, disregard this erroneous DTC. Attempts at
erasing this erroneous DTC will be unsuccessful.
If the vehicle IS equipped with auto headlamps, diagnose the DTC using **the appropriate Caravan,
Voyager and Town & Country Body Diagnostic Procedures Manual.**
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations > Component Locations
Body Control Module: Component Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Locations > Component Locations > Page 7828
Body Control Module Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions
Body Control Module: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7831
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7832
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7833
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7834
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7835
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7836
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7837
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7838
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7839
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7840
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7841
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7842
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7843
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7844
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7845
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7846
Body Control Module: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7847
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7848
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7849
Body Control Module: Connector Views
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7850
Body Control Module: Electrical Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7851
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7852
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7853
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7854
Exterior Lighting (Park Lamps)
Information Center
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7855
Instrument Cluster
Interior Lighting
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7856
Power Door Locks W/Remote Keyless Entry (RKE)
Power Door Locks W/O Remote Keyless Entry (RKE)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7857
Radio (CCD) Without Infinity Sound
Radio (CCD) With Infinity Sound
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7858
Vehicle Communications
Vehicle Theft Security System (VTSS)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7859
Windshield Wiper (Front)
Windshield Wiper (Rear)
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7860
Body Control Module (Part 1 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7861
Body Control Module (Part 2 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7862
Body Control Module (Part 3 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7863
Body Control Module (Part 4 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7864
Body Control Module (Part 5 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7865
Body Control Module (Part 6 Of 7)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Diagrams > Diagram Information and Instructions > Page 7866
Body Control Module (Part 7 Of 7)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service Precautions > Technician Safety Information
Body Control Module: Technician Safety Information
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following approved procedures is very important to the safety of individuals performing
diagnostic tests.
DANGER!!! Engines produce carbon monoxide that is odorless, causes slower reaction time, and
can lead to serious injury. When the engine is operating, keep service areas WELL VENTILATED
or attach the vehicle exhaust system to the shop exhaust removal system.
Set the parking brake and block the wheels before testing or repairing the vehicle. It is especially
important to block the wheels on front-wheel drive vehicles; the parking brake does not hold drive
wheels.
When servicing a vehicle, always wear eye protection, and remove any metal jewelry such as
watchbands or bracelets that might make an inadvertent electrical contact.
When diagnosing a body system problem, it is important to follow approved procedures where
applicable. Following these procedures is very important to the safety of individuals performing
diagnostic tests
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Service Precautions > Technician Safety Information > Page 7869
Body Control Module: Vehicle Damage Warnings
Before disconnecting any control module, make sure the ignition is "OFF". Failure to do so could
damage the module.
When testing voltage or continuity at any control module, use the terminal side (not the wire end) of
the connector. Do not probe a wire through the insulation; this will damage it and eventually cause
it to fail because of corrosion.
Be careful when performing electrical tests so as to prevent accidental shorting of terminals. Such
mistakes can damage fuses or components. Also, a second code could be set, making diagnosis of
the original problem more difficult.
When replacing a blown fuse, it is important to use only a fuse having the correct amperage rating.
The use of a fuse with a rating other than indicated may result in a dangerous electrical system
overload. If a properly rated fuse continues to blow, it indicates a problem in the circuit that must be
corrected.
When replacing lamp bulbs, do not touch the new bulb with your fingers. Oil contamination will
severely shorten bulb life. If the bulb comes in contact with an oily surface, clean the bulb with
rubbing alcohol.
Road Testing a Complaint Vehicle
Some complaints will require a test drive as part of the repair verification procedure. The purpose
of the test drive is to try to duplicate the diagnostic code or symptom condition.
CAUTION: Before road testing a vehicle, be sure that all components are reassembled. During the
test drive, do not try to read the DRB screen while in motion. Do not hang the DRB from the rear
view mirror or operate it yourself. Have an assistant available to operate the DRB.
Vehicle Preparation for Testing
Make sure the vehicle being tested has a fully charged battery. If it does not, false diagnostic codes
or error messages may occur.
Servicing Sub-Assemblies
Some components of the body system are intended to be serviced in assembly only. Attempting to
remove or repair certain system sub-components may result in personal injury and/or improper
system operation. Only those components with approved repair and installation procedures in the
service manual should be serviced.
DRBIII Safety Information
WARNING: Exceeding the limits of the DRB multimeter is dangerous. It can expose you to serious
or possibly fatal injury. Carefully read and understand the cautions and the specification limits.
^ Follow the vehicle manufacturer's service specifications at all times.
^ Do not use the DRB if it has been damaged.
^ Do not use the test leads if the insulation is damaged or if metal is exposed.
^ To avoid electrical shock, do not touch the test leads, tips, or the circuit being tested.
^ Choose the proper range and function for the measurement. Do not try voltage or current
measurements that may exceed the rated capacity.
^ Do not exceed the limits shown in the table below:
FUNCTION/INPUT LIMIT
Volts 0 - 500 peak volts AC 0 - 500 volts DC
Ohms (resistance)* 0-1.12 megohms
Frequency Measured 0 - 10 kHz
Frequency Generated 0 - 10 kHz
Temperature -58 - 11000 F -50 - 600 C
* Ohms cannot be measured if voltage is present. Ohms can be measured only in a non-powered
circuit.
^ Voltage between any terminal and ground must not exceed 500v DC or 500v peak AC.
^ Use caution when measuring voltage above 25v DC or 25v AC.
^ The circuit being tested must be protected by a 1OA fuse or circuit breaker.
^ Use the low current shunt to measure circuits up to 10A. Use the high current clamp to measure
circuits exceeding 10A.
^ When testing for the presence of voltage or current, make sure the meter is functioning correctly.
Take a reading of a known voltage or current before accepting a zero reading.
^ When measuring current, connect the meter in series with the load.
^ Disconnect the live test lead before disconnecting the common test lead.
^ When using the meter function, keep the DRB away form spark plug or coil wires to avoid
measuring error form outside interference.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Application and ID > Body Code
Body Control Module: Application and ID Body Code
Chrysler Town and Country/Dodge Caravan/Grand Caravan/Plymouth Voyager/Grand Voyager
Body Code = NS
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Application and ID > Body Code > Page 7872
Body Control Module: Application and ID Glossary of Terms
ACM Airbag Control Module AECM Airbag Electronic Control Module ASDM Airbag System
Diagnostic Module BCM Body Control Module CAB Controller Antilock Brake CCD Chrysler
Collision Detection (Vehicle Communications Bus) CCM Climate Control Module CMTC
Compass/Mini-Trip Computer (module) DLC Data Link Connector (previously "Engine Diagnostic
Connector") DR Driver DTE - Distance To Empty ECO - Economy EIC - Electronic Instrument
Cluster ET - Elapsed Time HVAC Heater, Ventilation, Air Condition IOD - Ignition Off Draw MET
Metric MIC Mechanical Instrument Cluster MUX Multiplexed ODO Odometer PASS Passenger
PCM Powertrain Control Module PDC Power Distribution Center PTC Positive Temperature
Coefficient RKE Remote Keyless Entry TCM Transmission Control Module VF Vacuum
Fluorescent Display VTSS Vehicle Theft Security System
NOTE: The following terms are used interchangeably:
- Left Front (LF) Door & Driver (DR) Door
- Right Front (RF) Door and Passenger (PASS) Door
- "Gage" and "Gauge"
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System
Body Control Module: Description and Operation Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7875
Body Control Module: Description and Operation Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7876
Body Control Module: Description and Operation Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7877
Body Control Module: Description and Operation Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7878
Body Control Module: Description and Operation
Airbag System
SYSTEM DESCRIPTION
The airbag system is designed to provide increased driver and passenger protection if the vehicle
is involved in a front end collision. The system is most effective when used in conjunction with the
seat belt system.
Both driver and passenger side airbag assemblies are now hybrid type which utilize a canister of
compressed, inert gas to inflate the bag, instead of sodium azide.
Currently, Chrysler Corporation uses two types of airbag control modules. The ASDM system is a
mechanically-triggered system utilizing two front impact sensors and a sensor inside the module.
The AECM (AB, AS, JA and NS bodies only) is an electronically-triggered system that uses only its
own internal electronic sensor to trigger the airbags. These procedures will address the AECM type
of module, the term "airbag control module" (or ACM) will be used to refer to the module.
FUNCTIONAL OPERATION
Whenever the ignition key is turned to the run or "start" position, the airbag control module (ACM)
performs a lamp check by turning the AIRBAG warning lamp on. The lamp stays lit for 6 to 8
seconds, then goes off. If the lamp remains off, it means that the ACM has checked the system and
found it to be free of discernible malfunctions. The airbag system is monitored by the ACM.
The ACM monitors critical input and output circuits within the airbag system, making sure they are
operating correctly. Some circuits are tested continuously; others are checked only under certain
circumstances. The ACM provides diagnostic information about the airbag system to the technician
through the DRB via the CCD bus.
The deceleration or g-force resulting from the impact of a front-end collision causes the electronic
sensor inside of the ACM to be triggered. This causes the inflators to be actuated, thus deploying
the airbags. The total time between determining to deploy and full inflation of the airbag is
approximately 40ms.
A new enhanced accident response feature has been added. This feature, upon deployment of the
airbag, turns on the interior lights and unlocks the power door locks (if equipped).
The AIRBAG warning lamp is the only point at which "symptoms" of a system malfunction can be
observed by the customer.
Use the test procedures to find the cause of any customer complaint regarding the AIRBAG
warning lamp, such as:
- warning lamp does not come on at all warning lamp stays on
Interior Lighting
This feature provides a battery protection scheme to avoid wearing down the battery due to leaving
a reading lamp on, glove box open or visor vanity mirrors on. The Body Control Module (BCM)
provides a ground circuit for these interior lamps. This ground path is connected whenever the
ignition is on but is always disconnected 15 minutes after the BCM enters sleep mode. Once the 15
minutes timeout has expired, any monitored input that brings the BCM out of sleep mode
(ignition/unlock switch, door ajar switches, dome lamp switch, RKE/Central Unlock actuation etc.)
will reset the 15 minute timer and return the reading, glove box lamps and vanity mirrors to normal
operation (normal operation defined as: "on" is reading lamp and visor vanity mirrors on, or glove
box open; "off" if reading lamp and visor vanity mirrors off, and glove box closed).
Leaving the keys in the ignition switch, while the ignition is off, will not inhibit the battery protection
from turning off these interior lamps as described above. Leaving the ignition switch in an active
position (steering column unlocked, ignition on or accessory power on) will inhibit the battery
protection routine from turning off these interior lamps as described above.
Body Control Module
The body control module (BCM) supplies vehicle occupants with visual and audible information and
controls various vehicle functions, To provide and receive information, the module is interfaced to
the vehicle's serial bus communications network (the Chrysler Collision Detection bus [or CCD
bus]). This network consists of the powertrain control module (PCM), the transmission control
module (TCM), the electro/mechanical instrument cluster (MIC), the airbag control module (ACM),
the compass/mini-trip module and the controller antilock brake (CAB) module. The BCM is
operational when battery power is supplied to the module. Ignition switch power is needed for
ignition switch functions.
The body control module provides the following features:
- automatic door locks
- battery protection
- chimes
- compass/mini-trip support
- courtesy lamps
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7879
- BCM diagnostic support
- door lock inhibit
- headlamp time delay
- ignition key lamp
- illuminated entry
- instrument panel dimming
- mechanical instrument cluster support
- power door locks (with/without remote keyless entry)
- sliding door memory lock
- vehicle theft security system (VTSS)
- windshield wipers / washers (front and rear)
Chime System
The chime system provides the driver with two types of chimes: warning and announcement.
Warning chimes are provided for dome lamps on, engine temperature lamp, exterior lamps on,
key-in ignition, low oil pressure, and turn signal on (greater than one mile above 15 mph). The
warning chime will sound continuously until the condition is removed or the battery protection stops
the chime (3 or 4 minutes). The driver seat belt unfastened chime will sound for approximately six
seconds or until the seat belt is fastened. The announcement chime will act as a warning to the
driver to scan the instrument cluster to observe which lamp is illuminated. The announcement
chime will sound one time whenever the generator lamp, low fuel, low washer fluid, door ajar, or
liftgate ajar lamps are first illuminated. The door and liftgate ajar lamp announcement chime is only
given if the vehicle speed is above 2 mph. Diagnostics for the announcement chime are covered
under the instrument cluster warning lamp diagnostics.
Compass Mini-Trip Computer (CMTC)
The compass/mini-trip computer is located in the overhead console. It displays to the driver the
direction the vehicle is traveling and the current outside temperature, as well as the following
traveler navigational information: average fuel economy (AVG ECO), distance to empty (DTE),
instantaneous fuel economy (ECO), elapsed time (ET), and trip odometer (ODO). The information
needed for the traveler functions is received over the CCD bus from the body control module.
If the compass/mini-trip computer has been replaced, it may be necessary to reset the calibration.
Auto Headlamps
On vehicles equipped with the auto headlamp feature, the Body Control Module (BCM) will control
the exterior lamp operation by monitoring the mode selection switch located in the headlamp
control panel. When auto headlamp mode is selected the BCM will then monitor for a on/off signal
from the Electo-Chromic Rear View Mirror. The mirror will determine the appropriate ambient light
levels for turning on/off the exterior lamps. If in auto headlamp mode, exterior lamps are on (due to
darkness), and the ignition switch is cycled off, the BCM will enter headlamp delay mode (see
Headlamp Delay Feature description).
Battery Protection: "Park & Headlamps"
This feature provides a battery protection scheme to avoid wearing down the battery if the
customer leaves the parklamps or headlamps on for extended periods of time with the ignition off. If
the parklamp or headlamp switch remains in the active position for more than 3 minutes, while the
ignition is off, the parklamps and or headlamps will be turned off and the input causing the lamps to
be on will be ignored. Once the 3 minute timeout has elapsed the Body Control Module (BCM) will
enter sleep mode. Any change in any inputs monitored by the BCM that brings the BCM out of
sleep mode, will reset the 3 minute timer (door lock/unlock, door ajar, ignition, Remote Keyless
Entry (RKE) actuation, etc.).
Leaving the ignition switch in an active position (steering column unlocked, ignition on or accessory
power on) will inhibit the battery protection routine from turning off the exterior lamps as described
above.
Exterior Headlamp Control
The headlamps and parklamps are illuminated via external relays which are controlled by the body
controller module (BCM). When the parklamp switch is closed to ground the BCM grounds the
parklamp relay coil which provides the power to the parklamps. This same parklamp power feed is
also wired back into the BCM to provide the power feed for the PWM circuit. When the headlamp
switch is closed to ground the BCM grounds both the low beam and high beam headlamp relays.
The position of the hi-beam select switch will determine the mode of operation.
Note: On Chrysler vehicle line when the high beams are selected both high beams and low beams
will be illuminated. Dodge and Plymouth vehicle lines support only one mode of operation at a time.
Headlamp Time Delay
The headlamp delay feature keeps the Headlamps on for 60 seconds giving the driver and
passengers security lighting when exiting the vehicle. This feature is only available on vehicles
equipped with remote keyless entry (RKE). The Headlamp Delay feature is activated by
sequentially turning off the ignition, then both the headlamps and parklamps. The headlamps and
parklamps must be turned off within 45 seconds of ignition transition to off to activate the headlamp
delay. This 45 second window is new for the NS body. Once the headlamp delay has been
activated the headlamps will remain on for 60 seconds or until a parklamp, headlamp, auto
headlamp or the ignition switch changes states.
Identification of System
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7880
The vehicle systems that are part of the "body" system are:
- airbag system
- chimes
- compass/mini-trip
- courtesy lamps I panel dimming
- headlamp time delay
- illuminated entry
- radio (CCD)
- information center
- mechanical instrument cluster (MIC)
- power door locks
- remote keyless entry (RKE)
- vehicle communications
- vehicle theft security system (VTSS)
- wipers
Vehicles equipped with the highline body control module can be identified by the presence of the
vehicle theft security system (VTSS). Vehicles with the midline body control module may have a
compass/mini-trip computer, power door locks, headlamp time delay, remote keyless entry, or
illuminated entry. Vehicles with a base body control module will not have any of these features.
Introduction
Diagnostic procedures change every year. New diagnostic systems may be added; carryover
systems may be enhanced. IT IS RECOMMENDED THAT YOU REVIEW THE ENTIRE TEST TO
BECOME FAMILIAR WITH ALL NEW AND CHANGED DIAGNOSTIC PROCEDURES. These
tests are designed to begin all diagnosis at SYMPTOM IDENTIFICATION TEST 1A. This will cover
all the necessary requirements to begin a logical diagnostic path for each repair. If there is a
trouble code detected, it will direct you to a specific test. If it is a symptom problem, it will direct you
to SYSTEM TEST 1A for more specific instructions or directly to a specific test. Side headers are
used to direct you alphabetically to the specific systems.
NOTE: The following terms are used interchangeably:
Left Front (LF) Door and Driver (DR) Door Right Front (RF) Door and Passenger (PASS) Door
Mechanical Instrument Cluster (MIC)
The body control module sends the angular position of the gauges, the status of all CCD indicator
lamps, the status and dimming of the mechanical instrument cluster - (MIC) over the CCD bus
when the ignition is in the "off" (unlock), "run", or "start" positions. The PRNDL (VF, if equipped)
and odometer/trip displays work when the ignition is in the "off" (unlock), "run", or "start" positions;
all other MIC features work only when the ignition is in the "run" position. On transition of the
ignition from the "off" to the "run" position, a bulb check is performed. This consists of activating all
CCD-controlled indicator lamps and all VF display segments for approximately 2-4 seconds. The
PRNDL bulb check is aborted if the gear selector is moved from the PARK position, or if the engine
exceeds 450 rpm.
Power Door Lock System
When the body control module (BCM) receives an input for a lock request (door lock switch, RKE,
or door key cylinder switch [only with VTSS]), it will ground the lock relay coil for a specified amount
of time ranging from 375 msec to 1 second. If the request is there beyond 1 second, the BCM
considers the door lock signal stuck and will turn the relay coil off. Once a door lock signal is stuck,
the signal input for that door is ignored until the stuck fault disappears. The unlock signal operates
in the same fashion as the lock signal. The door lock switches provide a variable amount of
resistance thereby dropping the voltage of the multiplexed (MUX) circuit and the BCM will respond
to that command.
Other power door lock features:
Sliding Door Memory Lock
When the BCM receives an input for a lock request and a sliding door is open, the BCM will turn on
the lock relay as described above, and will turn it on again when all sliding doors are closed.
NOTE: If the BCM receives an unlock input before a sliding door is closed this action will cancel the
memory lock.
Door Lock Inhibit
When the key is in the ignition and in the off position, and any door except the rear liftgate is open,
all door lock switches are disabled. The unlock switches are still functional. This protects against
locking the vehicle with the keys still in the ignition.
Automatic Door Locks
This feature can be enabled or disabled by using either the DRBIII or customer programming
method. When enabled, all the doors will lock when the vehicle reaches a speed of 15 MPH and all
doors are closed. If a door is opened and the vehicle slows to below 15 MPH, the door locks will
operate again once all doors are closed and the speed is above 15 MPH.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7881
RKE (Remote Keyless Entry) Interface
The body control module interfaces with the RKE receiver via a one-way serial bus interface. The
RKE receiver sends a 0-5 volt pulse width signal to the BCM depending on which button on the
transmitter was pressed. The BCM controls the door lock/unlock relays and arming/disarming of
the Vehicle Theft Security System (if equipped). The RKE receiver is capable of retaining up to 4
individual vehicle access codes (4 transmitters). If the PRNDL is in any position except park, the
BCM will ground the interface wire thereby disabling the RKE.
The RKE module can be programmed via the DRBIII or customer programming method. The BCM
will only allow programming mode to be entered when the ignition is in the on position, the PRNDL
is in park position, and the VTSS (if equipped) is in the disarmed mode.
Radio System
There are three radio systems available this year that will be on the CCD bus. They are the RBR,
RBN and RAZ models. The main reason they are on the bus is because of the radio remote
controls in the steering wheel. They can control volume up/down, seek up, seek down and preset
station selections. These systems also communicate with the body control module and will set a
specific code if there is a problem with the remote controls.
The RBR will have 4 speakers and the others will have 8 speaker locations (infinity sound). All of
the 4 main quarter speakers have a built in amplifier. The instrument panel and pillar speakers
receive their signals from the quarter speakers. Depending on the manufacture some systems will
have a Front/Rear channel system and others will have a Left/Right channel system. If one of the
main quarter speaker audio circuits experiences a short, the other speakers on that channel will
also shut down until the circuit is repaired. The radio will also set a trouble code, which is
assessible with the DRB, indicating which channel is effected.
Remote Keyless Entry (RKE) /Vehicle Theft Security System (VTSS)
This passive system is designed to protect against theft. The vehicle theft security system (VTSS)
is part of the body control module, which monitors vehicle hood, doors, liftgate, and ignition for
unauthorized operation. The alarm activates by sounding the horn, flashing the headlamps, park
and tail lamps, and the VTSS indicator lamp, and providing an engine "no run" feature.
Passive arming occurs upon normal vehicle exit by turning the ignition off, opening the driver's
door, locking the doors with the power lock, and closing the driver's door or locking the doors with
Remote Keyless Entry (RKE). Manual arming occurs by using the key to lock the doors after
closing them. The indicator lamp in the information center will flash for 15 seconds, showing that
arming is in progress. If no monitored systems are activated during this period, the system will arm.
If the hood ajar switch is seen as closed circuit by the system, the indicator lamp will remain
steadily lit during the arming process, although the system will still arm.
When something triggers the alarm, the system will signal the headlamps, park lamps, and horn for
about 3 minutes.
Tamper Alert - If the horn sounds three times when either front door or the liftgate is unlocked, it
means the alarm was activated. Check the vehicle for tampering.
Manual Override - The system will not arm if the doors are locked using the manual lock control (by
hand) or if the locks are actuated by an inside occupant after the door is closed.
When an unauthorized entry into the vehicle occurs, the VTSS sends a message via the CCD bus
to the powertrain control module that it is not OK to start the engine. The powertrain control module
then zeroes out the pulse width to the fuel injectors after the engine has been started, thus shutting
down the engine (start and stall condition). The engine will not start until the system is disarmed.
To verify the system, proceed as follows:
1. Open the driver's door. 2. Remove the ignition key (but keep it in hand). 3. Lock the doors with
the power lock switch. 4. Close the driver's door.
NOTE: After the doors are closed, locking the doors with RKE will also arm the system.
NOTE: If the VTSS indicator lamp flashed, the system is operational and verified. If not, there may
be a problem with the system.
System initialization is accomplished by:
1. Opening the hood to ensure the hood ajar circuit is closed. 2. Rotating the key in liftgate cylinder
to unlock/disarm position.
Arming/Disarming - Active arming occurs when the remote keyless entry transmitter is used to lock
the vehicle doors, whether the doors are open or closed. If one or more doors are open, the arming
sequence is completed only after all doors are closed.
Passive disarming occurs upon normal vehicle entry (unlocking either front door or the liftgate with
the key). This disarming also will halt the alarm once it has been activated.
Active disarming occurs when the remote keyless entry transmitter is used to unlock the vehicle
doors. This disarming also will halt the alarm once it has
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7882
been activated.
System Self-Test
NOTE: System self-test can be entered only with the DRB.
NOTE: A powertrain control module from a vehicle equipped with a vehicle theft security system
cannot be used in a vehicle that is not equipped with a vehicle theft security system.
If the VTSS indicator lamp comes on after ignition ON and stays on, the CCD bus communication
with the powertrain control module possibly has been lost.
Shipping Mode
By definition, shipping mode is when the Ignition Off-Draw (IOD) fuse is removed from the vehicle.
The Body Control Module (BCM) receives its primary power feed from the battery via the IOD fuse.
The BCM also receives a back-up power feed from the ignition Run/Start signal. During shipping
mode the illuminated entry, courtesy lamps, key-in lamps, reading lamps and glove box lamps will
not operate until the IOD is reconnected or the ignition switch is turned to the run/start position.
Six-Step Troubleshooting Procedure
Diagnosis of the body system is done in six basic steps:
- verification of complaint
- verification of any related symptoms
- symptom analysis
- problem isolation
- repair of isolated problem
- verification of proper operation
System Coverage
These diagnostic procedures cover 1998 Chrysler Town & County, Dodge Caravan, and Plymouth
Voyager vehicles equipped with either base, midline, or highline body control modules.
Airbag Trouble Code Descriptions
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of the trouble codes. It
is not necessary to perform all of the tests in the airbag section to diagnose an individual code.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
"AIRBAG" TEST 1A - Testing System Function. This will direct you to the specific test(s) that must
be performed. If more than one code exists, diagnostic priority should be given to the active
code(s).
Active diagnostic trouble codes for the airbag system are not permanent and will change the
moment the reason for the code is corrected. In certain test procedures, diagnostic trouble codes
are used as a diagnostic tool.
Active Codes
An active diagnostic trouble code indicates an on-going malfunction. This means that the defect is
currently there every time the airbag control module checks that circuit/function. It is impossible to
erase an active code; active codes automatically erase by themselves when the reason for the
code has been corrected.
With the exception of the warning lamp trouble codes or malfunctions, when a malfunction is
detected, the AIRBAG lamp remains lit for a minimum of 12 seconds or as long as the malfunction
is present.
Stored Codes
An airbag trouble code becomes active and stored as soon as it is detected with the exception of
the Loss of Ignition Run Only code, which is an active code only.
A "stored" code indicates there was an active code present at some time. However, the code
currently may not be present as an active code, although another active code could be.
When a trouble code occurs, the AIRBAG warning lamp illuminates for 12 seconds minimum (even
if the problem existed for less than 12 seconds). The code is stored, along with the time in minutes
it was active, and the number of times the ignition has been cycled since the problem was last
detected.
The minimum time shown for any code will be one minute, even if the code was actually present for
less than one minute. Thus, the time shown for a code that was present for two minutes 13
seconds, for example, would be three minutes.
If a malfunction is detected, a diagnostic trouble code is stored and will remain stored as long as
the malfunction exists. When and if the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7883
malfunction ceases to exist, an ignition cycle count will be initiated for that code. If the ignition cycle
count reaches 100 without a reoccurrence of the same malfunction, that diagnostic trouble code is
erased and that ignition cycle counter is reset to zero. If the malfunction reoccurs before the count
reaches 100, then the ignition cycle counter will be reset and the diagnostic trouble code will
continue to be a stored code.
If a malfunction is not active while performing a diagnostic test procedure, the active code
diagnostic test will not locate the source of the problem. In this case, the stored code can indicate
an area to inspect.
If no obvious problems are found, erase stored codes, and with the ignition "On" wiggle the wire
harness and connectors. Recheck for codes periodically as you work through the system. This
procedure may uncover a malfunction that is difficult to locate.
Airbag Diagnostic Trouble Codes
The airbag control module may report any of the following diagnostic trouble codes.
For the these codes, replace the airbag control module (ACM) even if set intermittently: AECM Accelerometer
- AECM Internal Diagnostic 2
- AECM Internal Diagnostic 1
- AECM Output Driver
- AECM Stored Energy
- Internal Diagnostic 3
- Incorrect AECM
For these codes, refer to the appropriate diagnostic procedure: Driver Squib Circuit Open
- No CCD Communication
- Driver Squib Circuit Shorted
- Passenger Squib Circuit Open
- Driver Squib Term Shorted to Battery
- Passenger Squib Circuit Shorted
- Driver Squib Term Shorted to Ground
- Pass Squib Term Shorted to Battery
- Loss of Ignition Run Only
- Pass Squib Term Short to Ground
- Loss of Ignition Run/Start
- Warning Lamp Circuit Open
- Output Driver Not Tested
- Warning Lamp Circuit Shorted
Driver Squib Circuit Open
NAME OF CODE
Driver Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring open or high resistance in clockspring
- Driver side airbag module open
- Driver airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Driver Squib Circuit Shorted
NAME OF CODE
Driver Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Clockspring short
- Driver side airbag module short
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7884
- Driver airbag line 1 shorted to line 2
- Loose, or poor connector not completely connected
Driver Squib Term Shorted to Battery
NAME OF CODE
Driver Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With the voltage on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to voltage
- Driver airbag line 2 short to voltage
- Faulty clockspring
- Faulty airbag control module
Driver Squib Term Shorted to Ground
NAME OF CODE
Driver Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the driver airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Driver airbag line 1 short to ground potential
- Driver airbag line 2 short to ground potential
- Faulty clockspring
- Faulty airbag control module
Loss of Ignition Run Only
NAME OF CODE
Loss of Ignition Run Only
NOTE: This code becomes active as soon as the condition is detected (this is not a stored code).
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Open ignition run circuit
- Open fuse
- Ignition run circuit short to ground
- Loose or poor connection at connector terminals
Loss of Ignition Run/Start
NAME OF CODE
Loss of Ignition Run/Start
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7885
- Open ignition run/start circuit
- Open fuse
- Ignition run/start circuit short to ground
- Loose or poor connection at connector terminals
Passenger Squib Circuit Open
NAME OF CODE
Passenger Squib Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) open
- Passenger airbag line 1 or line 2 open
- Loose or poor connection at connector terminals
Passenger Squib Circuit Shorted
NAME OF CODE
Passenger Squib Circuit Shorted
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
POSSIBLE CAUSES
- Passenger side airbag module (squib) short
- Passenger airbag line 1 shorted to line 2
- Loose or poor connection at connector terminals
Pass Squib Term Shorted to Battery
NAME OF CODE
Pass Squib Term Shorted to Battery
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to voltage
- Passenger airbag line 2 short to voltage
- Faulty airbag control module
Pass Squib Term Shorted to Ground
NAME OF CODE
Pass Squib Term Shorted to Ground
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
With voltage and current on, the passenger airbag line 1 or line 2 circuit(s) is other than expected.
POSSIBLE CAUSES
- Passenger airbag line 1 short to ground potential
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7886
- Passenger airbag line 2 short to ground potential
- Faulty airbag control module
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NAME OF CODE
Warning Lamp Circuit Shorted or Warning Lamp Circuit Open
NOTE: This code becomes active and stored as soon as the malfunction is detected.
WHEN MONITORED
With the ignition on, the ACM needs to turn the lamp on because of detection of a malfunction, or
during a lamp check.
SET CONDITION
With the voltage on, the airbag warning lamp driver circuit is other than expected.
POSSIBLE CAUSES
- Faulty warning lamp
- Open fused ignition switch output circuit to Information Center
- Airbag warning lamp driver circuit short to ground
- Airbag warning lamp driver circuit short to voltage
- Faulty information center printed circuit board
- Loose or poor connection at connector terminal
Output Driver Not Tested
NAME OF CODE
Output Driver Not Tested
WHEN MONITORED
At ignition on.
SET CONDITION
This code may set whenever another code is set due to any short to battery or short to ground
failure of the squib circuits. If all other squib codes have been repaired and this code appears
active by itself, the problem will be an internal failure of the airbag control module.
POSSIBLE CAUSES
- Short circuit to ground or to battery in either driver or passenger airbag lines
- Defective airbag control module
Trouble Code Testing Notes
Each diagnostic trouble code is diagnosed by following a specific testing procedure. The diagnostic
test procedures contain step-by-step instructions for determining the cause of trouble codes. It is
not necessary to perform all of the tests to diagnose an individual code.
The body control module will set a diagnostic trouble code if a monitored input is determined to be
malfunctioning and the trouble code condition remains active for 10 consecutive seconds. Once the
trouble code condition is removed, the body control module will back out the diagnostic trouble
code if the trouble code condition remains cleared for twenty ignition cycles.
Always begin by reading the diagnostic trouble codes using the DRB. This procedure begins with
the Symptom Identification TEST-1A - Identifying Vehicle Equipment and System Problems. This
will direct you to the specific test(s) that must be performed.
ASB Message Not Received
NAME OF CODE
ASB Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from CAB every second. If this message is not received by the BCM
for more than 14 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from CAB to BCM
Airbag Message Not Received
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7887
NAME OF CODE
Airbag Message Not Received
WHEN MONITORED
Continuously with ignition on.
SET CONDITION
BCM receives CCD message from ACM every second. It this message is not received by the BCM
for more than 18 seconds, this code will be set. This trouble code is stored in memory for 20 key
cycles after the problem is repaired if it is not erased after repair.
POSSIBLE CAUSES
- No response from ACM to BCM
Battery Power to Module Disconnected
NAME OF CODE
Battery Power to Module Disconnected
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
Battery power to the BCM is disconnected while the ignition is on.
THEORY OF OPERATION
The body control module checks battery input and determines if the battery is connected.
POSSIBLE CAUSES
- In shipping mode - IOD fuse missing
- Open wire
- Blown IOD fuse
EATX PRNDL Message Test Failed
NAME OF CODE
EATX PRNDL Message Test Failed
WHEN MONITORED
When engine is running.
SET CONDITION
The engine is running above 450 rpm and the body control module has not received a transmission
PRNDL message.
THEORY OF OPERATION
The body control module will monitor the CCD bus and look for the transmission PRNDL message
whenever the engine rpm is above 450.
POSSIBLE CAUSES
- Body Control module
- Transmission control module
- CCD bus failure
- Loss of power to transmission control module
EEPROM Checksum Failure
NAME OF CODE
EEPROM Checksum Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The sum of EEPROM constants does not equal the correct value.
THEORY OF OPERATION
By using a checksum, the BCM monitors the value of each programmable constant. The code is
set if any value is incorrect.
POSSIBLE CAUSES
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7888
- Body Control module
Front Wiper Park Switch CKT Open
NAME OF CODE
Front Wiper Park Switch Ckt Open
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left the park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Open wire
- Wiper motor
- Body Control module
Front Wiper Park Switch CKT-Shorted
NAME OF CODE
Front Wiper Park Switch Ckt-Shorted
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts and wiper
motor turned on.
SET CONDITION
The BCM, while monitoring the dwell switch, cannot determine when the wiper has left or returned
to the park position.
THEORY OF OPERATION
The BCM interfaces with the front wiper motor and performs wiper functions based upon the input
voltage from the multi-function switch. The BCM drives the wiper motor throughout the entire wiper
cycle. The BCM, while monitoring the dwell switch, can determine when the wiper has left park
switch and when it returns. When it fails to receive that information, it sets this code.
The wiper will run in low speed only and stop whenever the switch is shut off.
POSSIBLE CAUSES
- Shorted wire
- Wiper motor
- Body Control module
Fuel Level Sending Circuit Error
NAME OF CODE
Fuel Level Sending Circuit Error
WHEN MONITORED
With the ignition key on and battery voltage above 10 volts.
SET CONDITION
When the BCM senses an open or short on the fuel level sensor signal circuit.
THEORY OF OPERATION
The BCM interfaces with the fuel level sending unit. This sensor will vary it's resistance based on
fuel level. If the input received from the fuel sensor is out of it's specified range, this code will be
set.
POSSIBLE CAUSES
- Open wire
- Shorted wire
- Fuel level sending unit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7889
- Body control module
Internal Module Test Failed
NAME OF CODE
Internal Module Test Failed
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The body control module performs an internal check and determines the body control module is not
functioning properly.
THEORY OF OPERATION
The body control module performs internal diagnostics on demand and determines if the body
control module microprocessor is functioning properly.
POSSIBLE CAUSES
- Body control module
Left Door Key CYL Arm SW Failure
NAME OF CODE
Left Door key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Key CYL Disarm SW Failure
NAME OF CODE
Left Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left door key cylinder switch
- Body control module
Left Door Lock Switch Failure
NAME OF CODE
Left Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7890
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Left Door Unlock Switch Failure
NAME OF CODE
Left Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the LF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted left front door switch
- Body control module
Liftgate Key CYL Arm SW Failure
NAME OF CODE
Liftgate Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Key CYL Disarm SW Failure
NAME OF CODE
Liftgate Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the liftgate switch MUX circuit for longer than
8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7891
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted liftgate key cylinder switch
- Body control module
Liftgate Door Mux CKT Short to GND
NAME OF CODE
Liftgate Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the liftgate switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (Liftgate Switch MUX)
- Body control module
LT Front Door Mux Circuit Short to GND
NAME OF CODE
LT Front Door MUX Circuit Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below 0.4 volts on the LF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (LF Door Switch MUX)
- Body control module
No CCD Message From PCM
NAME OF CODE
No CCD Message From PCM
WHEN MONITORED
When the ignition is in the run or start position and battery voltage is above 10 volts.
SET CONDITION
The BCM looks for engine messages over the CCD bus and does not receive a message within a
2-second period.
THEORY OF OPERATION
The body control module will monitor the engine messages after the ignition has been turned on.
POSSIBLE CAUSES
- Body control module
- Powertrain control module
- CCD Bus failure
Rear Wiper Mux Circuit Error
NAME OF CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7892
Rear Wiper MUX Circuit Error
WHEN MONITORED
With the ignition in the run or accessory position and battery voltage above 10 volts.
SET CONDITION
When the rear wiper MUX circuit senses a voltage above 5.0 volts.
THEORY OF OPERATION
The BCM interfaces with the climate control module (CCM) to perform the rear wiper function. The
CCM, based upon which rear wiper function is selected, will send the BCM a varying voltage level.
The voltage level will determine the wiper function to be performed. That level will be below 5.0
volts.
POSSIBLE CAUSES
- Circuit shorted to battery
- Open CCM ground circuit
Right Door Key CYL Arm SW Failure
NAME OF CODE
Right Door Key Cyl Arm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 4.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Key CYL Disarm SW Failure
NAME OF CODE
Right Door Key Cyl Disarm Sw Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 2.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right door key cylinder switch
- Body control module
Right Door Lock Switch Failure
NAME OF CODE
Right Door Lock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 3.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7893
THEORY OF OPERATION
The BCM interfaces with the power coor lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
Right Door Unlock Switch Failure
NAME OF CODE
Right Door Unlock Switch Failure
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage of 1.0 volts (+/-250mV) on the RF door switch MUX circuit for longer
than 8 seconds.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted right front door lock switch
- Body control module
RT Front Door Mux CKT Short to GND
NAME OF CODE
RT Front Door MUX Ckt Short to Gnd
WHEN MONITORED
Anytime battery voltage is above 10 volts and BCM is awake.
SET CONDITION
The BCM senses a voltage below .4 volts on the RF door switch MUX circuit.
THEORY OF OPERATION
The BCM interfaces with the power door lock, unlock, arm and disarm switches via a single wire
circuit (Door Switch MUX) for each door zone. Each zone functions independently of each other.
Each switch inside the door has a unique resistance value which when activated sends a voltage
level to the BCM. The BCM will interpret the different levels and perform the desired function.
POSSIBLE CAUSES
- Shorted wire (RF Door Switch MUX)
- Body control module
Horn Switch Failure
NAME OF CODE
Horn Switch Failure
WHEN MONITORED
Continuously with battery connected and IOD fuse installed.
SET CONDITION
The BCM has sole control of the horn relay. The BCM will monitor the horn switch (in the steering
wheel) for an active signal and will sound the horn. If the horn switch remains grounded for more
than 30 seconds, the BCM will turn off the horn output and 10 seconds later will set the code. The
horn will remain disabled until the horn switch is ungrounded for 22 seconds to allow the horn to
cool down.
POSSIBLE CAUSES
- Shorted horn relay control circuit
- Defective horn switch
- Defective BCM
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7894
CCD Radio
NAME OF CODE
CCD Radio Volume Up Switch (Stuck) Seek Up Switch (Stuck) Seek Down Switch (Stuck) Volume
Down Switch (Stuck) Preset Switch (Stuck)
WHEN MONITORED
Anytime ignition is on and voltage is above 10.0 volts.
SET CONDITION
When a switch is held active for longer than 20 seconds.
THEORY OF OPERATION
The BCM monitors the control switches for an active condition and performs the required radio
function. When a switch is active for longer than 10 seconds, that switch function will be disabled
until the switch is sensed inactive. If the switch is active for longer than 20 seconds a code will be
set.
POSSIBLE CAUSES
- Defective remote control switch
- Shorted radio control MUX circuit
Vehicle Communication
The body system consists of a combination of modules that communicate over the Chrysler
Collision Detection multiplex system (CCD) bus. Through the CCD bus, information about the
operation of vehicle components and circuits is relayed to the appropriate module(s). Each module
receives the same information about a component or circuit as the other modules do. This
significantly reduces the complexity of the wiring in the vehicle and the size of the wiring
harnesses.
The Chrysler Collision Detection multiplex system (CCD bus) consists of a twisted pair of wires.
These wires run from one module to another. They receive and deliver coded information between
the modules. The information is coded to identify the message as well as the importance of the
message. When there are multiple messages trying to access the CCD bus at one time, the code
determines the message that has the highest priority, which is then allowed to access the bus first.
The two wires of the twisted pair that make up the CCD multiplex system are called "bus +" (bus
plus) and "bus -" (bus minus) respectively. Each wire has a measurable voltage level of roughly 2.5
volts. In order to maintain the 2.5 volts on each line and provide a means of transportation for the
coded messages, there is a "voltage divider network". This network consists of some modules with
bias and some with termination. Bias is the part of the voltage divider network that places both bus
+ and bus - at 2.5 volts. Termination in the circuitry is required to complete the voltage divider
network and also provides some electromagnetic protection for the bus.
NOTE: Communication over the bus is essential to the proper operation of the vehicle's on-board
diagnostic systems and the DRB. Problems with the operation of the bus or DRB must be corrected
before proceeding with diagnostic testing. If there is a problem, refer to the Vehicle
Communications section.
Any of the following bus failure messages may be displayed.
Short to Battery - Either or both of the bus wires are shorted to the battery potential.
Short to 5 Volts - Either or both of the bus wires are shorted to a 5-volt potential.
Short to Ground - Either or both of the bus wires are shorted to ground or a specific ground may be
open.
Bus (+) & Bus (-) Shorted Together - The two bus wires are shorted together.
No Termination - The bus system has lost connection with all of its terminators.
Bus Bias Level Too Low - Either of both of the bus wire potentials are significantly below their
normal 2.5 volts.
Bus Bias Level Too High - Either of both of the bus wire potentials are significantly above their
normal 2.5 volts.
No Bus Bias - The bus system has lost connection with all modules that provide bias.
Bus (+) Open - The bus (+) wire has lost connection with termination and/or bias.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Description and Operation > Airbag System > Page 7895
Bus (-) Open - The bus (-) wire has lost connection with termination and/or bias.
Not receiving Bus Messages Correctly - The DRB cannot communicate over the bus and does not
know why.
Wiper System
FRONT
The front wiper system provide the driver with normal wipe (low and high speeds), intermittent
wipe, wipe after wash, and pulse wipe functions. The driver selects the wiper function via a
resistive multiplexed stalk switch mounted on the steering column. When the wiper is in the on
position and the ignition is turned off, the wiper will continue to run until it reaches its park position.
Other front wiper system features:
Speed Sensitive Intermittent Wipe Mode - There are 6 individual delay times with a minimum delay
of 1/2 second to a maximum of 18 seconds. When the vehicle speed is under 10 MPH, the delay
time is doubled to provide a range time of from 1 second to 36 seconds.
Pulse Wipe - When the wiper is in the off position and the driver presses the wash button for more
than 62 msec but less than 1/2 second, 1 wipe cycle in low speed mode will be provided.
Wipe After Wash Mode - When the driver presses the wash button for over 1/2 second and then
releases it, the wiper will continue to run for 2 additional wipe cycles.
REAR
The rear wiper system provides the driver with continuous, intermittent, and wiper after wash
functions. The driver selects the wiper function via a resistive multiplexed switch mounted in the
HVAC control.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Component Tests and General Diagnostics
Body Control Module: Component Tests and General Diagnostics
SELF DIAGNOSTIC TEST
To activate self diagnostic program: 1. With the ignition switch in the OFF position, depress the
TRIP and RESET buttons. 2. While holding the TRIP and RESET button turn the ignition switch to
the ON position. 3. Continue to hold the TRIP and RESET buttons until the word code appears in
the odometer windows (about five seconds) then release the
buttons. If a problem exists, the system will display diagnostic trouble codes. If no problem exists
the code 999 (End Test) will momentarily appear.
INSTRUMENT CLUSTER DTC CHART
DTC .....................................................................................................................................................
.................................................... Description 110 ...............................................................................
.......................................................................................................... Memory Fault in cluster 111 .....
..............................................................................................................................................................
................... Calibration fault in cluster 905 .........................................................................................
................................................................................ No CCD bus messages from TCM 921 ..............
..............................................................................................................................................................
......... Odometer fault from BCM 940 ...................................................................................................
...................................................................... No CCD bus messages from PCM 999 ........................
..............................................................................................................................................................
.................... End of Codes
NOTE: For DTC testing see Condition Diagnostic Charts below.
CONDITIONS
Refer to the following Diagnostic Charts: Instrument Cluster See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Instrument Cluster Diagnosis
- Speedometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Speedometer Diagnosis
- Tachometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Tachometer Diagnosis
- Fuel Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Fuel Gauge Diagnosis
- Temperature Gauge See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Temperature Diagnosis
- Odometer See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Odometer Diagnosis
- Electronic Transmission Range Indicator (PRND3L) See: Instrument Panel, Gauges and Warning
Indicators/Testing and Inspection/Diagnostic Charts/Electronic Gear Indicator Display Diagnosis
- Mechanical Transmission Range Indicator (PRND21) for possible/problems/causes and
corrections See: Instrument Panel, Gauges and Warning Indicators/Testing and
Inspection/Diagnostic Charts/Mechanical Transmission Range Indicator (PRND21)
CALIBRATION TEST
When CHEC-1 is displayed in the odometer window, each of the cluster's gauge pointers will move
sequentially through each calibration point. The Calibration Table contains the proper calibration
points for each gauge. If the gauge pointers are not calibrated, a problem exists in the cluster. If
any gauge is out of calibration it will have to be calibrated using a scan tool (DRB III).
CLUSTER CALIBRATION TABLE
Speedometer .......................................................................................................................................
................................................. Calibration Point
1 ...........................................................................................................................................................
............................................... 0 mph (0 Km/h) 2 .................................................................................
..................................................................................................................... 20 mph (40 Km/h) 3 .......
..............................................................................................................................................................
................................. 55 mph (80 Km/h) 4 ...........................................................................................
.......................................................................................................... 75 mph(120 Km/h)
Tachometer .........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
............................................................... 0 rpm 2 ................................................................................
.................................................................................................................................... 1000 rpm 3 .....
..............................................................................................................................................................
................................................. 3000 rpm 4 ........................................................................................
............................................................................................................................ 6000 rpm
Fuel Gauge ..........................................................................................................................................
................................................ Calibration Point
1 ...........................................................................................................................................................
......................................................... Empty(E) 2 .................................................................................
................................................................................................................................... 1/8 Filled 3 .......
..............................................................................................................................................................
............................................... 1/4 Filled 4 ...........................................................................................
............................................................................................................................ Full (F)
Temperature Gauge ............................................................................................................................
............................................... Calibration Point
1 ...........................................................................................................................................................
.......................................................... Cold (C) 2 .................................................................................
.............................................................................................................................. Low Normal 3 .......
..............................................................................................................................................................
......................................... High Normal 4 ............................................................................................
........................................................................................................................... Hot (H)
DIM TEST
When CHEC-0 is displayed in the odometer window, the cluster's vacuum fluorescent (VF) displays
will dim down. If the VF display brightness does
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Component Tests and General Diagnostics > Page 7898
no change, a problem exists in the cluster.
ODOMETER SEGMENT TEST
When CHEC-2 is displayed in the odometer window, each digit of the odometer will illuminate
sequentially If a segment in the odometer does not illuminate normally, a problem exists in the
display.
ELECTRONIC TRANSMISSION RANGE INDICATOR SEGMENT TEST
When CHEC-3 is displayed in the odometer window, each segment of the transmission range
indicator will illuminate sequentially. If a segment in the transmission range indicator does not
illuminate normally, a problem exists in the display board.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Component Tests and General Diagnostics > Page 7899
Body Control Module: Scan Tool Testing and Procedures
Refer to the DRB user's guide for instructions and assistance with reading trouble codes, erasing
trouble codes, and other DRB functions.
DRBIII Error Messages
Under normal operation, the DRB will display one of only two error messages:
- User-Requested WARM Boot or User-Requested COLD Boot
If the DRB should display any other error message, record the entire display and call the scantool
manufacturer for information and assistance. This is a sample of such an error message display:
ver: 2.14 date: 26 Jul93 file: key_itf.cc date: Jul26 1993 line: 548 err. Oxi User-Requested COLD
boot
Press MORE to switch between this display and the application screen. Press F4 when done
noting information.
DRBIII Does Not Power Up (Blank Screen)
If the LED's do not light or no sound is emitted at start up, check for loose cable connections or a
bad cable. Check the vehicle battery voltage (data link connector cavity 16). A minimum of 11 volts
is required to adequately power the DRB.
If all connections are proper between the DRB and the vehicle or other devices, and the vehicle
battery is fully charged, an inoperative DRB may be the result of faulty cable or vehicle wiring.
Perform Vehicle Communication TEST 1A
Display is Not Visible
Low temperatures will affect the visibility of the display. Adjust the contrast to compensate for this
condition.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Page 7900
Body Control Module: Service and Repair
Body Control Module Location
REMOVAL
1. Disconnect battery negative cable. 2. Remove lower steering column cover and knee blocker
reinforcement. 3. Disconnect two wire connectors from bottom of Body Control Module (BCM) 4.
Remove bolts holding junction to dash panel mounting. 5. Remove Junction Block from mounting
bracket. 6. Remove screws holding Body Control Module to Junction Block. 7. Slide Body Control
Module downward to disengage guide studs on Junction Block from channels on BCM mounting
bracket. 8. Remove Body Control Module from Junction Block.
INSTALLATION
1. Install Body Control Module from Junction Block. 2. Slide Body Control Module upward to
engage guide studs on Junction Block from channels on BCM mounting bracket. 3. Install screws
holding Body Control Module to Junction Block. 4. Install Junction Block from mounting bracket. 5.
Install bolts holding junction to dash panel mounting. 6. Connect two wire connectors from bottom
of Body Control Module (BCM) 7. Install lower steering column cover and knee blocker
reinforcement. 8. Connect battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Body Control Systems > Body Control Module > Component Information >
Testing and Inspection > Page 7901
Body Control Module: Tools and Equipment
The following tools are recommended to properly diagnose CCD bus problems:
- Scan tool -- with correct cartridge and applicable connectors.
- Jumper Wires
- Ohmmeter
- Oil Pressure Gauge (0-300 psi)
- Test Light
- Voltmeter
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer
Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer
Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7910
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer
Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7911
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer
Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7912
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > Customer
Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 7913
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page
7919
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page
7920
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page
7921
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Cowl > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page
7922
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Handle > Front
Door Exterior Handle > System Information > Service and Repair
Front Door Exterior Handle: Service and Repair
EXTERIOR HANDLE
REMOVAL
1. Roll door glass up. 2. Remove the watershield. (Refer to Front Door Panel.) 3. Through access
hole at rear of inner door panel, disconnect Vehicle Theft Security System (VTSS) switch connector
from door harness, if
equipped.
4. Disengage push in fasteners attaching VTSS switch harness to inner door reinforcement bar, if
equipped. 5. Disengage clip holding door latch linkage to door latch. 6. Remove latch linkage from
latch. 7. Disengage clip holding door lock linkage to door latch. 8. Remove lock linkage from latch.
Fig. 19
9. Remove nuts holding outside door handle to door outer panel (Fig. 19). 10. Remove outside
door handle from vehicle.
INSTALLATION
If outside door handle replacement is necessary, transfer lock cylinder from the original handle to
the new one.
1. Place outside door handle in position on vehicle. 2. Install nuts attaching outside door handle to
door outer panel (Fig. 19) . 3. Insert lock linkage into door latch. 4. Engage ,clip to hold door lock
linkage to latch. 5. Insert latch linkage into door latch. 6. Engage clip to hold door latch linkage to
latch. 7. Install push-in fasteners to hold VTSS switch harness to inner door reinforcement bar, if
equipped. 8. Connect VTSS switch connector into door harness, if equipped. 9. Verify door latch
operation.
10. Install sound shield and door trim panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Front Door > Front Door Window Motor
> Component Information > Service and Repair
Front Door Window Motor: Service and Repair
WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN SECTOR GEAR AREA WHERE THEY
CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE.
REMOVAL 1. Tape the window in its existing position to remove its weight from the regulator
system. 2. Cut and remove the tie wrap at the window motor. Its no longer required. 3. Disconnect
window motor wire connector from door harness. 4. Remove screws and nuts holding window
motor to the inner panel. 5. Remove the motor from the door inner panel, let it hang from the
cables. 6. With the cables still attached to the failed motor, Install the replacement motor to the
door inner panel. Tighten down the screws and nuts to 3.4 to
4.5 N.m ( 30 to 40 in. lbs.) of torque.
7. Separate the failed motor from regulator by:
- Removing the drum cover plate.
Power Window Motor Removal
- Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously.
CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION 1. Install the cable guide and drum into the replacement motor.
CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the
drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor
shaft by a slight rotation, then, the glass should be lowered a small amount approximately 1 to 2
inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance
of a second person.
2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the
wiring harness to the window motor connector. 4. Remove the tape holding the window in place
and test window operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Doors > Sliding Door > Sliding Door Handle >
Component Information > Service and Repair
Sliding Door Handle: Service and Repair
EXTERIOR HANDLE
REMOVAL
1. Remove sliding door trim panel. 2. Remove sliding door stop bumper. 3. Peel watershield away
from adhesive around perimeter of inner door panel as necessary to access outside release handle
fasteners. 4. Remove latch/lock control cover. 5. Disengage clip holding outside door handle
linkage to door handle. 6. Remove linkage from outside door handle. 7. Remove linkage from
latch/lock control.
Fig. 31
8. Remove nuts holding outside door handle to outer door panel (Fig. 31). 9. Remove outside door
handle from vehicle.
INSTALLATION
1. Position outside door handle on vehicle. 2. Install nuts attaching outside door handle to outer
door panel. 3. Insert linkage into outside door handle. 4. Engage clip to hold linkage to outside door
handle. 5. Engage rigging-cam to latch/lock control mechanism. 6. Move clip on latch/lock control
to bottom of slot and engage linkage to latch/lock control. 7. Verify sliding door operation. Adjust as
necessary. 8. Install latch/lock cover. 9. Place the watershield into position and press securely to
adhesive making sure to properly route wiring and linkages.
10. Install sliding door stop bumper. 11. Install sliding door trim panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service
and Repair
Fuel Door: Service and Repair
REMOVAL
1. Remove left quarter trim panel. 2. Remove water shield patch covering access hole in C-pillar. 3.
Disengage latch release link from clip on fuel fill blocker latch arm. 4. Open fuel fill door. 5. Remove
screws holding fuel fill neck to fuel filler housing. 6. Position fuel fill neck out of the way.
7. Reaching inside fuel filler housing, release clips holding housing to quarter panel. 8. Remove
fuel fill door from vehicle.
9. Disengage clip holding link to fuel fill door.
10. Remove link from fuel fill door.
INSTALLATION
1. Install spring to housing and door 2. Snap door into housing. 3. Insert lockout link into clip on fuel
fill door. 4. Engage clip to hold link to fuel fill door. 5. Insert lockout link through grommet in panel
between inner and outer quarter panel. 6. Close fuel fill door. 7. Install fuel filler housing to outer
quarter panel. 8. Verify that all clips on fuel filler housing are fully engaged to outer quarter panel.
9. Place fuel fill neck in position.
10. Install screws to hold fuel fill neck to fuel filler housing. 11. Engage latch release link into clip on
fuel fill blocker latch arm. 12. Verify fuel fill blocker latch operation. 13. Install water shield patch to
cover access hole in C-pillar.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Fuel Door > Component Information > Service
and Repair > Page 7940
14. Install left quarter trim panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Doors, Hood and Trunk > Hood > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger
switch from top of the radiator closure panel.
Hood Ajar Switch
3. Disconnect the trigger switch from the wire connector and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications
Cross-Member: Specifications
To Body Attaching Bolts ......................................................................................................................
................................................ 163 Nm (120 ft. lbs.) Reinforcement Plate Attaching Bolts M-12
............................................................................................................................................ 108 Nm
(80 ft. lbs.) Reinforcement Plate Attaching Bolts M-14
.......................................................................................................................................... 166 Nm
(123 ft. lbs.) Cradle Plate To Cradle Attaching Bolts
............................................................................................................................................... 165 Nm
(123 ft. lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Page
7950
Cross-Member: Description and Operation
This vehicle uses a one piece cast aluminum cradle for the front suspension. The cradle is used as
the attaching points for the lower control arms, stabilizer bar and steering gear. The cradle also has
the power steering hoses and the chassis brake tubes attached to it.
The cradle is mounted to the front frame rails at four points, two on each side of the vehicle. The
cradle is isolated from the body of the vehicle using four isolators, one located at each mounting
bolt location.
CAUTION: If a threaded hole in the suspension cradle needs to be repaired, only use the type of
thread insert and installation procedure specified for this application. The threaded holes in the
cradle that are used for attachment of the lower control arm rear bushing retainer, power steering
hose and chassis brake tubes can be repaired. The repair is done by the installation of a Heli-Coil
thread insert, or equivalent which has been specifically developed for this application.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Cross-Member > Component Information > Specifications > Page
7951
Cross-Member: Service and Repair
CAUTION: When performing this procedure use only the thread inserts which are specified in the
Mopar (R) Parts Catalog, or equivalent for this repair procedure. These thread inserts have been
specifically developed for this application and use of other types of thread inserts can result in an
inferior long term repair.
SUSPENSION CRADLE THREAD REPAIR PROCEDURE
The threaded holes in the front suspension cradle, if damaged, can repaired by installing a
Heli-Coil (R) thread insert.
The threaded holes that are repairable using the thread insert, are the lower control arm rear
bushing retainer mounting bolt holes, routing bracket attaching locations for the power steering
hoses, and brake hose attachment holes.
This repair procedure now allows the threaded holes in the suspension crossmember to be
repaired, eliminating the need to replace the crossmember if damage occurs to one of the threaded
holes.
The thread inserts for this application are specified by part number in the Mopar (R) Parts Catalog.
Do not use a substitute thread insert.
The specific tools and equipment required to install the thread insert are listed below. Refer to the
instructions included with the thread insert for the detailed procedure used for the installation of the
thread insert.
NOTE: The thread inserts for this application are for the repair of M8 x 1.25 and M10 x 1.5 threads.
Be sure the correct tools are used for the required thread insert size.
TOOL REQUIREMENT FOR M8 x 1.25 THREAD
- 8.3 mm (5/16 inch) Drill Bit
- 120° Countersink
- Heli-Coil (R) Tap #4863-8
- Heli-Coil (R) Gage #4624-8
- Heli-Coil (R) Hand Inserting Tool 7751-8
- Needle Nose Pliers - For Removal Of Thread Insert Driving Tang
TOOL REQUIREMENT FOR M10 x 1.5 THREAD
- 10.5 mm (25/64 inch) Drill Bit
- 120° Countersink
- Heli-Coil (R) Tap #4863-10
- Heli-Coil (R) Gage #4624-10
- Heli-Coil (R) Hand Inserting Tool 7751-10
- Needle Nose Pliers - For Removal Of Thread Insert Driving Tang
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front
Crossmember
Subframe: Service and Repair Front Crossmember
REMOVAL AND INSTALLATION FRONT CROSSMEMBER
The front suspension crossmember must be installed in the design location to achieve proper front
end suspension alignment. If the crossmember is removed without applying reference marks on the
frame rails, align the crossmember according to the dimensions provided in this group.
NOTE: If the caged nuts in the frame rails become damaged and cannot be reused, a replacement
nut can be obtained through a Mopar Parts supplier.
REMOVAL
1. Disconnect battery negative cable. 2. Remove steering column lower cover from instrument
panel. 3. Remove knee blocker reinforcement. 4. Position steering so front wheels are straight
ahead.
CAUTION: DO NOT ROTATE STEERING WHEEL AFTER DISENGAGING LOWER COUPLING
FROM STEERING GEAR, DAMAGE TO AIRBAG CLOCK SPRING CAN RESULT.
Steering Coupling Boot
5. Remove clinch bolt holding steering column coupling to steering gear shaft. 6. Remove steering
column coupling from telescoping steering gear shaft. 7. Hoist and support vehicle on safety
stands. 8. Position a drain pan under power steering pump and oil return hose coupling. 9. Using
hose pinch-off pliers C-4390, pinch power steering oil return hose off between the cross-member
coupling and the pump.
10. Loosen hose clamp at the crossmember coupling. 11. Disconnect return hose from metal tube.
12. While holding pressure relief valve nut on back of power steering pump. Remove flare nut
holding high pressure hose to back of pump. 13. Separate high pressure hose from pump. 14.
Allow power steering fluid to drain into pan. 15. Remove bolts holding anti-lock brake sensor leads
to crossmember. 16. Position anti-lock brake leads out of the way. 17. Disconnect stabilizer bar
links from ends of stabilizer bar. Refer to Steering and Suspension. 18. Disconnect lower ball joints
from lower control arms. Refer to Steering and Suspension.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front
Crossmember > Page 7956
Rear Engine Mount
19. Remove bolt holding rear engine mount to crossmember. 20. Using paint or grease pencil,
mark outline of crossmember on frame rails to aid installation.
Crossmember
21. Support crossmember on suitable lifting device.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front
Crossmember > Page 7957
Crossmember Mount
22. Remove bolts holding crossmember to front frame rails.
Crossmember
23. Remove crossmember from vehicle.
INSTALLATION
NOTE: If crossmember requires replacement. Refer to Steering and Suspension, to transfer
steering and suspension components.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front
Crossmember > Page 7958
Crossmember
1. Support crossmember on suitable lifting device. 2. Position crossmember to vehicle. 3. Loosely
install bolts to hold crossmember to front frame rails. 4. Align crossmember to previously made
marks on frame rails. 5. Tighten bolts holding crossmember to frame rails. 6. Install bolt holding
rear engine mount to cross-member. 7. Connect lower ball joints to lower control arms. Refer to
Steering and Suspension. 8. Connect stabilizer bar links to ends of stabilizer bar. Refer to Steering
and Suspension 9. Install bolts to hold anti-lock brake sensor leads to crossmember.
10. Install high pressure hose to pump. 11. Connect return hose to metal tube. 12. Tighten hose
clamp at the crossmember coupling. 13. Remove pinch-off pliers. 14. Position steering so front
wheels are straight ahead. 15. Install steering column coupling to telescoping steering gear shaft.
16. Install clinch bolt to hold steering column coupling to steering gear shaft. 17. Install knee
blocker reinforcement. 18. Install steering column lower cover from instrument panel. 19. Connect
battery negative cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Frame > Subframe > Component Information > Service and Repair > Front
Crossmember > Page 7959
Subframe: Service and Repair Front Crossmember Mount Bushings
FRONT CROSSMEMBER MOUNT BUSHINGS
REMOVAL
1. Using paint or grease pencil, mark outline of crossmember on frame rails. 2. Loosen bolts
holding crossmember to frame rails. 3. Remove bolt on bushing that requires replacement. 4. Allow
crossmember to drop down enough to gain clearance for bushing removal. 5. Remove bushing
from vehicle.
INSTALLATION
1. Apply rubber lube or soap to replacement bushing. 2. Insert lower half of bushing into square
hole in crossmember. 3. Place upper half of bushing on top of cross-member aligned to receive
square tube protruding upward from lower bushing half. 4. Squeeze bushing halves together to
ensure they are properly mated. 5. Lift crossmember upward to close gap between the bushing and
frame. 6. Verify that lower bushing is fully seated into crossmember and upper bushing. 7. Install
bolt to hold bushing and crossmember to frame rail hand tight. 8. Align crossmember to reference
marks on frame rails. 9. Tighten crossmember to frame rails attaching bolts to 163 Nm 120 ft. lbs.
torque.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions
Console: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7965
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7966
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7967
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7968
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7969
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7970
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7971
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7972
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7973
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7974
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7975
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7976
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7977
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7978
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7979
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7980
Console: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7981
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7982
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7983
Console: Electrical Diagrams
Overhead Console (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7984
Overhead Console (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Diagram Information and Instructions > Page 7985
Overhead Console (Part 3 Of 3)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Page 7986
Console: Description and Operation
SYSTEM OPERATION
Compass Mini Trip Computer (CMTC) The Compass mini-trip computer (CMTC) system is located
in the overhead console. CMTC consists of an electronic control module with a vacuum fluorescent
display (VFD) and function switches. The CMTC consists of an electronic module that displays
compass, trip computer and temperature features. Actuating the STEP switch will cause the CMTC
to change mode of operation when the ignition is ON.
Examples: Compass/Temperature
- Trip odometer (ODO)
- Average miles per gallon (ECO)
- Instant miles per gallon (ECO)
- Distance to empty (DTE)
- Elapsed time (ET)
- Off
The CMTC module in the overhead console has three buttons used to select various functions. The
CMTC selector buttons will not operate until the ignition is in the RUN position.
When the ignition switch is first turned to the Run position the CMTC display: Blanks momentarily
- All segments of the VFD will light for one second
- Blanks momentarily
- Returns to the last mode setting selected before the ignition was last switched OFF.
Thermometer Engine temperature can increase the displayed temperature. The CMTC is designed
to dampen temperature readings when the vehicle is moving at a rate slower than 18 miles per
hour.
The outside temperature is measured from a sensor mounted in the front of the vehicle. If the
temperature is more than 55 °C (131 °F) or the temperature sending line is shorted to ground, the
temperature display should read SC. If the temperature is less than -40 °C (-40 °F), or the sending
line is an open circuit, the display should read 0C.
The CMTC will not allow the temperature reading to increase when the vehicle is not moving.
Compass The CMTC is self calibrating and usually requires no adjustment. The compass will
continuously perform a slow calibration to compensate for small magnetic variations common to
any automobile. Uncommon magnetic shifts may be caused by items such as magnetic base
antennas, which can permanently alter the magnetic field of the vehicle roof panel. If excessive
magnetic field continues for 5 minutes, the compass heading will go blank and only the CAL
symbol will illuminate. When this occurs, the vehicle roof panel may require demagnetizing. Refer
to the demagnetizing procedure.
Moderate magnetic shifts may, on very rare occasions, cause the compass heading to display only
one or two of the eight possible headings. Although the compass will eventually compensate for
this shift, it could take several ignition cycles. The compensation process can be expedited by
manually activating the fast calibration routine. Refer to the fast calibrating procedure. This
procedure may be performed anytime that the compass appears to be inaccurate.
If the calibration data stored in the body control module is not received, the compass will read only
NE North-East. The CMTC is self calibrating and requires no adjusting. The word CAL is displayed
to show that the compass is in calibration mode. CAL will turn off after the vehicle has gone
through three complete circles without stopping, in an area free of magnetic disturbance. If module
displays temperature while the compass is blank, turn off ignition and run self diagnostics then
demagnetize the vehicle. After demagnetizing, check compass calibration number, refer to Self
Diagnostic Test. If greater than 15, demagnetize again until reading is less than 15. If compass still
goes blank after demagnetizing then check internal diagnostics and demagnetize.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Diagrams >
Page 7987
Universal Transmitter Location
Universal Transmitter The Universal Transmitter, replaces the hand held remote controls that open
the garage door, motorized gates, or home lighting in/outside the home. This device memorizes the
activator codes for up to three remote controlled devices. It triggers those devices at the push of a
button, located in a unit permanently mounted in your overhead console (if equipped).
The transmitter operates off your vehicle's battery and charging system; no batteries are needed.
The Universal Transmitter incorporates a Rolling Code technology (random digital code signals
from the remote transmitter) within the transmitter module. This is done so, as an added security
measure.
Features of the Universal Transmitter are: Can be used with most other Radio Frequency (RF) activated devices.
- Individual channels can be trained.
- Stores transmitter data in permanent memory - retraining is not required even if the battery dies or
is disconnected.
To operate, simply press the appropriate button on the Universal Transmitter. The red LED will light
up while the signal is being transmitted.
NOTE: For security reasons, you are able to erase the trained frequencies.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console Replacement
Console: Service and Repair Console Replacement
REMOVAL
Lower Console
1. Remove screws holding lower console to floor bracket and instrument panel. 2. Slide console
rearward from around instrument panel supports. 3. Remove lower console.
INSTALLATION
1. Place lower console in position. 2. Slide console forward around instrument panel supports. 3.
Install screws to hold lower console to floor bracket and instrument panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console Replacement > Page 7990
Console: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb
REMOVAL
1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading
lamp bulb socket one quarter turn counter clockwise.
Reading/Courtesy Lamp
3. Pull socket out of lamp. 4. Pull bulb from socket.
INSTALLATION
1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter
turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens
onto lamp lens pivots.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Console Replacement > Page 7991
Console: Service and Repair Overhead Console Replacement
REMOVAL
Overhead Console
1. Open the transmitter bin door. 2. Remove screw holding the overhead console to the headliner.
- With the screw removed the console is retained by one engagement tab located inside the
eyeglass storage bin.
3. Open the eyeglass bin door. 4. Press the retaining tab which is located directly above the door
latch. 5. Lower rear of console away from headliner. 6. Pull console rearward to disengage clips
holding front of console to roof armature and lower console. 7. Disconnect wire connectors from
back of CMTC and reading lamps.
- Ensure the connectors lock tabs are fully depressed before disconnecting.
8. Remove overhead console.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Console > Component Information > Service and
Repair > Page 7992
Degausser 6029
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Dashboard / Instrument Panel > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 7999
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Convenience Bin Track
Drink Holders: Service and Repair Convenience Bin Track
Convenience Bin Access Cover
REMOVAL
1. Remove the convenience bin track from the instrument panel or the ash receiver, if equipped. 2.
Remove the screw access cover from the bottom of the radio bezel. 3. Remove the center bezel.
Convenience Bin Access Cover
4. Remove the convenience bin track attaching screws and pull the convenience bin track rearward
to disengage the rear guide studs from instrument
panel.
5. Disengage the clip holding convenience bin lamp to track. 6. Remove the convenience bin.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Convenience Bin Track > Page 8004
Drink Holders: Service and Repair Convenience Bin Lamp
Unused Convenience Bin Lamp Socket Location
If the lamp is not used refer to -- Wiring For The Convenience Lamp.
REMOVAL
1. Pull out the convenience bin cup holder. 2. Insert the trim stick between access cover above cup
holder and center console.
Convenience Bin Access Cover
3. Carefully pry the access cover from the center console. 4. Separate the access cover from the
vehicle. 5. Using needle-nose pliers, carefully squeeze the vertical metal legs of the lamp hood. 6.
Lift the lamp hood upward from the cup holder tray
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Convenience Bin Track > Page 8005
Convenience Bin Lamp Bulb
7. Carefully pull the lamp and wiring rearward from the instrument panel. 8. Pull the lamp hood from
the lamp socket. 9. Pull bulb from socket.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Drink Holders > Component Information >
Service and Repair > Convenience Bin Track > Page 8006
Drink Holders: Service and Repair Convenience Bin - Cup Holder
Ash Receiver - Cup Holder
REMOVAL
1. Pull the convenience bin open. 2. Push lock tab at rear center downward. 3. Pull the
convenience bin - cup holder from track in instrument panel. 4. Remove convenience bin - cup
holder.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Glove Compartment > Glove Compartment Lock
> Component Information > Service and Repair
Glove Compartment Lock: Service and Repair
REMOVAL
Glove Box Lamp Striker
1. Open glove box door. 2. Disengage clip holding check straps to glove box door. 3. Remove
screws holding lock striker to instrument panel. 4. Remove glove box lock striker.
INSTALLATION
1. Install glove box lock striker. 2. Install screws holding lock striker to instrument panel. 3. Engage
clip holding check straps to glove box door.
Glove Box Lamp Striker
4. Close glove box door.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair
Trim Panel: Service and Repair
REMOVAL
1. Using a trim stick (C-4755), pry courtesy lamp from door trim. 2. Disconnect wire connector from
courtesy lamp. 3. If equipped, remove screws attaching door assist handle to inner door panel. 4. If
equipped, remove screw attaching door pull cup to inner door panel. 5. If equipped, remove screws
attaching trim panel to door from below map pocket. 6. If equipped, remove window crank. 7. Using
a trim stick, remove screw cover from switch panel. 8. Remove screws attaching switch panel to
door trim.
Fig.32 Front Door Switch Panel
9. Remove power accessary switch from door trim.
10. Disconnect power switch from wire connector.
Fig.33 Memory Seat/Mirror Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > Page 8014
11. If equipped, using a small, flat bladed pry tool, remove memory seat/mirror switch and
disconnect wire connector. 12. If equipped, remove screw holding door trim to door panel from
behind inside latch release handle.
Fig.34 Front Door Trim Panel
13. Disengage clips attaching door trim to door frame around perimeter of panel. 14. Lift trim panel
upward to disengage flange from inner belt molding at top of door. 15. Tilt top of trim panel away
from door to gain access to latch linkage.
Fig.35 Inside Door Handle Linkage
16. Disengage clip attaching linkage rod to inside latch release handle. 17. Separate linkage rod
from latch handle. 18. Remove front door trim panel from vehicle.
INSTALLATION
1. Hold top of trim panel away from door to gain access to latch linkage. 2. Place linkage rod in
position on latch handle. 3. Engage clip to hold linkage rod to inside latch release handle. 4. Place
front door trim panel in position on door. 5. Install trim panel into inner belt molding at top of door.
6. Install clips to attach door trim to door frame around perimeter of panel. 7. If equipped, install
screw to attach door trim to door panel behind inside latch release handle. 8. If equipped, connect
power switch into wire connector. 9. Place power accessary switch in position on door trim.
10. Connect wire connector into memory seat/mirror switch and install switch into trim panel. 11.
Install screws to attach accessary switch panel to door trim. 12. Install screw cover into switch
panel. 13. If equipped, install window crank. 14. If equipped, install screws to attach trim panel to
door inside map pocket.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Interior Moulding / Trim > Trim Panel > Component Information > Service
and Repair > Page 8015
15. If equipped, install screw to attach door pull cup to inner door panel. 16. If equipped, install
screws to attach door assist handle to inner door panel. 17. Connect wire connector into courtesy
lamp. 18. Install lamp in door trim.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations > Page 8021
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations > Page 8022
Keyless Entry Module: Adjustments
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30
seconds or when ignition switch is turned OFF, the
RKE module will end the programming mode. A single chime will sound to verify that the RKE
module will no longer receive additional Vehicle Access Code(s).
7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each
key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Module > Component Information >
Locations > Page 8023
Keyless Entry Module: Service and Repair
REMOVAL
1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel.
RKE Module
3. Disconnect wire connector from RKE module. 4. Remove the RKE module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry
Transmitter Battery > Component Information > Technical Service Bulletins > Customer Interest for Keyless Entry
Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure
Keyless Entry Transmitter Battery: Customer Interest RKE Transmitter - Premature Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely
MODELS:
1997 - 1998 (AB) Ram Van/Wagon
1997 - 1998 (AN) Dakota/Dakota Cab & Chassis
1998 (BRIBE)Ram Truck
1998 (DN) Durango
1997 (LH) Concorde/Intrepid/LHS/Vision
1997 - 1998 (NS) Town & Country/Caravan/Voyager
1997 - 1998 (PL) Neon
1997 (PR) Prowler
1997 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX).
SYMPTOM/CONDITION:
Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH
0815XX, perform the Repair Procedure.
PARTS REQUIRED:
AR 04686366 Transmitter, RKE- NS, PL & PR
AR 04759136AB Transmitter, RKE- LH
AR 56007049 Transmitter, RKE- AB & 1997 AN
AR 56008761 Transmitter 1, RKE- ZJ & DN
AR 56008762 Transmitter 2, RKE- ZJ
AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitter(s).
1. Replace RKE transmitter(s) that have discharged batteries.
2. Program the RKE transmitter(s) to the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-28-93 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry
Transmitter Battery > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Keyless
Entry Transmitter Battery: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure
Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature
Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely
MODELS:
1997 - 1998 (AB) Ram Van/Wagon
1997 - 1998 (AN) Dakota/Dakota Cab & Chassis
1998 (BRIBE)Ram Truck
1998 (DN) Durango
1997 (LH) Concorde/Intrepid/LHS/Vision
1997 - 1998 (NS) Town & Country/Caravan/Voyager
1997 - 1998 (PL) Neon
1997 (PR) Prowler
1997 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX).
SYMPTOM/CONDITION:
Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH
0815XX, perform the Repair Procedure.
PARTS REQUIRED:
AR 04686366 Transmitter, RKE- NS, PL & PR
AR 04759136AB Transmitter, RKE- LH
AR 56007049 Transmitter, RKE- AB & 1997 AN
AR 56008761 Transmitter 1, RKE- ZJ & DN
AR 56008762 Transmitter 2, RKE- ZJ
AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitter(s).
1. Replace RKE transmitter(s) that have discharged batteries.
2. Program the RKE transmitter(s) to the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-28-93 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Keyless Entry > Keyless Entry Transmitter > Keyless Entry
Transmitter Battery > Component Information > Technical Service Bulletins > Page 8038
Keyless Entry Transmitter Battery: Application and ID
The batteries can be removed without special tools and are readily available at local retail stores.
The recommended battery is Duracell DL 2016 or equivalent. Battery life is about one to two years.
CAUTION: Do not touch the battery terminals or handle the batteries any more than necessary.
Hands must be clean and dry.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 >
Sliding Door Power Lock Actuator - Chatter Sound
Power Door Lock Actuator: Customer Interest Sliding Door Power Lock Actuator - Chatter Sound
NUMBER: 23-042-00
GROUP: Body
DATE: Nov. 3, 2000
SUBJECT: Sliding Door Power Lock Actuator Chatter Sound
OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to
eliminate the plunger lifting away from the lock lever when in the lock position.
MODELS: 1996 - 2000
(NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power
lock feature is repeatedly activated.
DIAGNOSIS:
Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three
times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair
Procedure.
NOTE:
REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE
COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO
TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS
TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the
2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and
available on MDS2).
2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control.
3. Remove the latch/lock control cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-042-00 > Nov > 00 >
Sliding Door Power Lock Actuator - Chatter Sound > Page 8048
4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA.
5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator
grommet as shown in (Fig. 1).
6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should
be heard from the actuator and the plunger should remain held under the lock lever during and
after actuation.
7. Install the latch/lock control cover.
8. Install the water shield.
9. Install the sliding door interior trim panel.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Customer Interest for Power Door Lock Actuator: > 23-03-99 > Feb > 99 >
Power Door Lock Motor - Whirling Noise
Power Door Lock Actuator: Customer Interest Power Door Lock Motor - Whirling Noise
NUMBER: 23-03-99
GROUP: Body
DATE: Feb. 12, 1999
SUBJECT: Power Door Lock Motor Whirling Noise
MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after
the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is
replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to
help improve Fix It Right (FIR) scores.
1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly
locking and then a minimum of five times repeatedly unlocking to discover any power door lock
motors that make a whirling noise, even intermittently.
2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise
by placing your ear near the rear of the suspect front door, then activate the power door locks to
confirm which side the whirling noise is coming from.
3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures
outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors
open) and activate the door locks a minimum of five times repeatedly locking and then a minimum
of five times repeatedly unlocking.
5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door.
(leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and
then a minimum of five times repeatedly unlocking.
7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor
Operation Time Schedule for operation number, time allowance and failure code.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov
> 00 > Sliding Door Power Lock Actuator - Chatter Sound
Power Door Lock Actuator: All Technical Service Bulletins Sliding Door Power Lock Actuator Chatter Sound
NUMBER: 23-042-00
GROUP: Body
DATE: Nov. 3, 2000
SUBJECT: Sliding Door Power Lock Actuator Chatter Sound
OVERVIEW: This bulletin involves installing a rubber 0-ring on the sliding door lock lever tab to
eliminate the plunger lifting away from the lock lever when in the lock position.
MODELS: 1996 - 2000
(NS) Town & Country/Caravan/Voyager
1996 - 2000 (GS) Chrysler Voyager (International Markets)
SYMPTOM/CONDITION:
A chatter sound may be heard coming from the sliding door power lock actuator(s) when the power
lock feature is repeatedly activated.
DIAGNOSIS:
Use the power door lock switch to perform an unlock - lock - lock cycle, repeat the cycle three
times, if a chatter sound is heard at one or both of the sliding door actuators, perform the Repair
Procedure.
NOTE:
REPEATING THE TEST MORE THAN 3 TIMES MAY TRIP THE POSITIVE TEMPERATURE
COEFFICIENT (PTC) CIRCUIT AND CAUSE THE CHATTER SOUND; CHATTER DUE TO
TRIPPING OF THE PTC IS NOT CONSIDERED A FAILURE. IF THE PTC CIRCUIT HAS
TRIPPED, WAIT ONE HOUR BEFORE RETRYING THE DIAGNOSIS.
PARTS REQUIRED:
REPAIR PROCEDURE:
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Remove the sliding door interior trim panel using the procedure outlined on page 23-52 of the
2000 Town & Country/Caravan/Voyager Service Manual (Publication No.81-370-0005 and
available on MDS2).
2. Carefully peel back the water shield to expose the plastic cover over the latch/lock control.
3. Remove the latch/lock control cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-042-00 > Nov
> 00 > Sliding Door Power Lock Actuator - Chatter Sound > Page 8058
4. Replace the lock actuator grommet (Fig. 1), with the one included in kit p/n 05072507AA.
5. Install the 0-ring from kit p/n 05072507AA, over the lock lever tab and against the actuator
grommet as shown in (Fig. 1).
6. Test by performing an unlock - lock - lock cycle, repeat the cycle three times. No chatter should
be heard from the actuator and the plunger should remain held under the lock lever during and
after actuation.
7. Install the latch/lock control cover.
8. Install the water shield.
9. Install the sliding door interior trim panel.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Power Door Lock Actuator: > 23-03-99 > Feb
> 99 > Power Door Lock Motor - Whirling Noise
Power Door Lock Actuator: All Technical Service Bulletins Power Door Lock Motor - Whirling Noise
NUMBER: 23-03-99
GROUP: Body
DATE: Feb. 12, 1999
SUBJECT: Power Door Lock Motor Whirling Noise
MODELS: 1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
DISCUSSION: Some front and/or sliding door power lock motors may make a whirling noise after
the lock actuator has reached its full travel. Sometimes the wrong door power lock motor is
replaced because of poor diagnosis procedures. The following diagnosis procedure is provided to
help improve Fix It Right (FIR) scores.
1. With all vehicle doors open, activate the power door locks a minimum of five times repeatedly
locking and then a minimum of five times repeatedly unlocking to discover any power door lock
motors that make a whirling noise, even intermittently.
2. If a noisy power door lock motor is heard, determine which side is producing the whirling noise
by placing your ear near the rear of the suspect front door, then activate the power door locks to
confirm which side the whirling noise is coming from.
3. If the front door power lock motor/latch(s) is found to be noisy, Replace it using the procedures
outlined on page 23-40 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
4. If the whirling noise was not heard in step 1, close the left sliding door (leave the front doors
open) and activate the door locks a minimum of five times repeatedly locking and then a minimum
of five times repeatedly unlocking.
5. If the whirling noise is heard replace the left sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
6. If the noise is not heard in step 4, open the left sliding door and close the right sliding door.
(leave the front doors open) Activate the door locks a minimum of five times repeatedly locking and
then a minimum of five times repeatedly unlocking.
7. If the whirling noise is heard replace the right sliding door latch/lock control using the procedures
outlined on page 23-52 of the 1999 Town & Country, Caravan, & Voyager Service Manual.
POLICY: Reimbursable within the provisions of the warranty. Refer to the appropriate Labor
Operation Time Schedule for operation number, time allowance and failure code.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Page 8063
Power Door Lock Actuator: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Page 8064
Power Door Lock Actuator: Testing and Inspection
Verify battery condition before testing door lock motor(s). To determine which motor is faulty, check
each individual door for electrical lock and unlock or disconnect the motor connectors one at a
time, while operating the door lock switch. In the event that none of the motors work, the problem
may be caused by a shorted motor, a relay or a bad switch. Disconnecting the defective motor will
allow the others to work.
Door Lock Motor Connector Pin Location
Front Door Lock Motor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Technical Service Bulletins > Page 8065
Lift Gate Release Assembly
To test an individual door lock motor, disconnect the electrical connector from the motor. To lock
the door, connect a 12 Volt power source to the positive pin of the lock motor and a ground wire to
the other pin. To unlock the door reverse the wire connections at the motor pin terminals. If these
results are NOT obtained, replace the motor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Liftgate Lock Motor
Power Door Lock Actuator: Service and Repair Liftgate Lock Motor
REMOVAL
1. Remove liftgate trim panel.
Liftgate Lock Motor
2. Remove bolts holding liftgate lock motor to lift-gate. 3. Disconnect the wire connector from power
lock motor. 4. Disconnect the liftgate lock motor from outside handle lock link. 5. Remove the
liftgate lock motor from vehicle.
INSTALLATION
1. Install the liftgate lock motor from vehicle. 2. Connect the liftgate lock motor from outside handle
lock link. 3. Connect the wire connector from power lock motor.
Liftgate Lock Motor
4. Install bolts holding liftgate lock motor to lift-gate. 5. Install liftgate trim panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Liftgate Lock Motor > Page 8068
Power Door Lock Actuator: Service and Repair Sliding Door Lock Motor
REMOVAL
1. Remove sliding door trim panel. 2. Remove watershield as necessary 3. Remove latch/lock
control cover. 4. Remove latch/lock control.
Sliding Door Lock Motor
5. Remove screws holding door lock motor to latch/lock control. 6. Remove lock motor from control.
INSTALLATION
1. Install lock motor from control.
Sliding Door Lock Motor
2. Install screws holding door lock motor to latch/lock control. 3. Install latch/lock control. 4. Install
latch/lock control cover. 5. Install watershield as necessary
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Actuator > Component
Information > Service and Repair > Liftgate Lock Motor > Page 8069
6. Install sliding door trim panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Relay > Component Information
> Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Locks > Power Locks > Power Door Lock Switch > Component Information
> Testing and Inspection
Power Door Lock Switch: Testing and Inspection
1. Remove door lock switch bezel assembly from door. 2. Disconnect wire connector from back of
door lock switch. 3. Depress switch to LOCK position.
Door Lock Switch
4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK
position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the
parameters shown replace the door lock switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description
and Operation
Heated Element: Description and Operation
SYSTEM OPERATION
Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only. The
heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the
rear window defogger is ON.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Heated Element, Mirror > Component Information > Description
and Operation > Page 8080
Heated Element: Testing and Inspection
Heated mirrors are available on models with Power Mirrors and Rear Window Defogger only The
heated mirror is controlled by the rear window defogger switch. The heated mirror is ON when the
rear window defogger is ON.
1. The mirror should be warm to the touch. 2. If not, check the 10 amp fuse (12) in the junction
block behind the instrument panel to the left of the steering column. 3. Test voltage at rear window
defogger switch.
- If no voltage repair wire.
Power Mirror Test
- Apply voltage to one wire and ground the other, refer for pin numbers. Mirror should become
warm to the touch.
- If not remove mirror glass and test the wires for continuity If no continuity repair wires.
- If wires are OK, replace mirror glass.
- To test defogger switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch >
Component Information > Description and Operation
Seat Memory Switch: Description and Operation
SYSTEM OPERATION
Memory Selector Switches The memory selector switches are mounted on the driver's door trim
panel within easy reach of the driver. They provide a means to set or recall either of two positions
of seat and recliner, and the side view mirrors as chosen by the driver.
The inputs from these switches to the memory seat/mirror module is a ground level signal. 1.
Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and
release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press
any switches for 10 seconds. 4. To program the second driver's position, follow the above
sequence. 5. To recall either of the programmed positions momentarily press and release either
memory selector switch 1 or 2.
Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing
requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum
hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must
be met for proper operation of the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch >
Component Information > Description and Operation > Page 8085
Seat Memory Switch: Testing and Inspection
To test the memory selector switch:
1. Remove the memory selector switch. Refer to removal procedure.
Memory Selector Switch Continuity
2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Memory Positioning Systems > Seat Memory Switch >
Component Information > Description and Operation > Page 8086
Seat Memory Switch: Service and Repair
REMOVAL
1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel.
2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Motor > Component Information > Testing and
Inspection
Power Mirror Motor: Testing and Inspection
1. Remove headlamp switch bezel. 2. Disconnect wiring harness connector to the power mirror
switch and headlamp switch. 3. Using two jumper wires:
- Connect one to a 12-Volt source
- Connect the other to a good body ground
Power Mirror Test
- Refer to the Mirror Test Chart for wire hookups at the switch connector.
4. If results shown in chart are not obtained, check for broken or shorted circuit, or replace mirror
assembly as necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Diagrams
Power Mirror/Window Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and
Inspection > Mirror Switch Test
Power Mirror Switch: Testing and Inspection Mirror Switch Test
1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch
connector.
Mirror Switch Test
3. Using a ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror
Switch Continuity Chart. 4. If results shown in the chart are not obtained, replace the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Testing and
Inspection > Mirror Switch Test > Page 8095
Power Mirror Switch: Testing and Inspection Side View Mirror Switch Stuck
The mirror switches in the instrument panel have normally open contacts when in their inactive
state. The left/right rocker switch has a center-off detent. If this switch is actuated to either side, it
then becomes connected to the P73/P70, circuits which are the mirror motor common connections.
No faults will result from this action by itself. If one of the other switch contacts from the round
portion of the switch becomes accidentally closed, It can cause problems such as both mirrors
operating at the same time in the vertical or horizontal modes.
Turn ignition switch ON: If two mirror switch contacts, from the round portion, are stuck in the
closed position, and the left/right portion is actuated to either side, a mirror motor will become
actuated. This will drive the motor to its stop, where it will keep ratcheting until a switch contact is
released or the ignition is turned to OFF. Replace the mirror switch assembly to correct this
condition.
- With the ignition switch in the ON or the OFF position: If only one mirror switch contact is stuck in
the closed position, the mirror motor will not become actuated. During an ignition switch recall of a
driver 5 chosen position, the Memory Seat/Mirror Module will attempt to drive the mirror motor only
if:
- The closed switch contact was the same as the desired direction
- Until the lack of a signal seen by the module shuts off the drive to the motor
The Memory Seat/Mirror Module will shut off the drive to the desired motor. It is possible that a
single stuck contact could place an opposite mirror or direction into a series connection. This would
run the connected motors at approximately half speed. Replace the mirror switch assembly to
correct this condition.
Mirror Mechanization
Mirror Mechanization Table
The 25-way connector at the Memory Seat/Mirror Module (under the driver's seat) and the mirror
mechanization show that both mirrors use the same functions. The rheostat for position sensing
utilizes the wire from the module to the mirror as both feed and sense line on the same wires, D
and F. The ground return wire, E, stands alone.
The mirror motors for each side use a common connection, B, which becomes automatically
connected to the proper polarity power connection during either manual (through the mirror switch)
or recall (through the Memory Seat/Mirror Module) modes of operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and
Repair > Power Mirror Switch
Power Mirror Switch: Service and Repair Power Mirror Switch
Power Mirror Switch
REMOVAL
1. Remove instrument cluster bezel. 2. Disconnect wire connector from back of power mirror
switch. 3. Disengage lock tabs above and below the mirror switch. 4. Pull power mirror switch from
headlamp switch bezel. 5. Remove power mirror switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Mirrors > Power Mirror Switch > Component Information > Service and
Repair > Power Mirror Switch > Page 8098
Power Mirror Switch: Service and Repair Power Mirror Switch Lamp
Power Mirror Switch Lamp
REMOVAL
1. Remove instrument cluster bezel. 2. Rotate bulb socket counter clockwise one quarter turn. 3.
Pull bulb socket from back of power mirror switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 8103
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 8104
Keyless Entry Module: Adjustments
1. Using a functional key fob transmitter, unlock the vehicle and disarm the Vehicle Theft Security
System. 2. Insert ignition key into the ignition switch. 3. Turn the ignition switch to RUN position
without starting engine. 4. Using a functional key fob transmitter, press and hold the UNLOCK
button for a minimum four seconds (maximum ten seconds). 5. While holding UNLOCK button, and
before ten seconds passes, press and release the PANIC button. A single chime will sound to
verify that the
RKE module is set to receive the new Vehicle Access Code(s).
6. Within 30 seconds of the chime, press any button on each new key fob transmitter. After 30
seconds or when ignition switch is turned OFF, the
RKE module will end the programming mode. A single chime will sound to verify that the RKE
module will no longer receive additional Vehicle Access Code(s).
7. When Vehicle Access Code(s) programming is complete, turn Ignition Switch to the OFF position
and verify RKE system operation using each
key fob.
NOTE: Only the primary (first two) key fob transmitters will operate the memory seat and mirror
systems. If a primary key fob is being replaced, the memory seat and mirror module will require
programming.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Keyless Entry Module >
Component Information > Locations > Page 8105
Keyless Entry Module: Service and Repair
REMOVAL
1. Remove instrument panel top cover 2. Remove screws holding RKE module to instrument panel.
RKE Module
3. Disconnect wire connector from RKE module. 4. Remove the RKE module.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Door Lock Relay >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Power Seat Control Module >
Component Information > Technical Service Bulletins > Memory Power Seat - Travel Range
Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT: Memory Power Seat Travel Range
MODELS:
1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand
Cherokee 1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and
remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in
MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the
motor end, fails to change. The feedback voltage potentiometers vary the position sensing
feedback voltage based on seat position/movement (no movement, no change in position sensing
feedback voltage). The seat motor automatically stops at the soft stop on any subsequent
movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when
something is stuck under or behind the seat that causes the seat to stop moving). These soft stops
can prevent the seat from being able to have memory positions set over the full range of travel.
Also, positions that were previously programmed to locations beyond an updated soft stop limit will
not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed
into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure
to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat
operation.
There are two potential reasons for intermittent memory functioning of the seats. The first
possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned
by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in
the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can
be caused by a poor connection at pin 23 of the P34 connector which is located near the right side
of the steering column. This circuit is used to communicate and control the seat module. This circuit
"locks out" movement when the vehicle is not in park and also causes seat position recall when
used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for
fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat
to move the seat in one direction to the end of travel, then energize the seat again in the same
direction until it stops and for three additional seconds after it stops. The amount that the seat
moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat
this procedure for each of the directions of movement (one at a time).
NOTE:
IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF
SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM
(AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE
MANUAL).
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation
Seat Heater Control Module: Description and Operation
SYSTEM OPERATION
The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate
the electric seat heater elements. Two modules are used in the vehicle, one for each front seat.
The HSCM for each seat is installed on front portion of each cushion pan. The wire harness
connector is secured by an integral clip to the inside surface of the outboard seat cushion frame.
Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat
cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery
feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 8116
Seat Heater Control Module: Testing and Inspection
Before testing the heated seat control module, test the heated seat switch, the heated seat
elements, and the heated seat sensor as described. If testing of the heated seat switch, elements,
and sensor reveals no problems, proceed as follows.
1. Replace the heated seat control module with a known good unit and test the operation of the
heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.
2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat
sensor to the heated seat control module. Repair any
short or open circuits as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Relays and Modules - Body and Frame > Seat Heater Control Module >
Component Information > Description and Operation > Page 8117
Seat Heater Control Module: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the
vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the
module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5.
Remove module from seat cushion pan.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > Customer Interest for Roof Rack Frame: > 23-14-98 > Apr > 98 > Roof Rack Rattles at Highway Speeds
Roof Rack Frame: Customer Interest Roof Rack - Rattles at Highway Speeds
NO: 23-14-98
GROUP: Body
DATE: Apr. 24, 1998
SUBJECT: Roof Rack Rattles At Highway Speeds
MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION: Roof rack rattles at speeds above 65 mph (105 kph). The rattle may be
heard at slower vehicle speeds when operating the vehicle in strong crosswinds or headwinds.
Rough road surfaces DO NOT have an effect on this condition.
DIAGNOSIS: If the vehicle operator describes the above condition, perform the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE: This bulletin involves installing revised roof rack crossrails.
1. Using the procedure outlined on page 23-51 of the 1998 Town & Country, Caravan and Voyager
service manual (Publication No. 81-370-8105) remove the roof rack crossrail and stanchion
assemblies.
2. Separate the stanchions from the crossrails and discard the crossrails.
3. Install the stanchions onto the revised crossrails.
4. Using the procedure outlined on page 23-52 of the 1998 Town & Country, Caravan and Voyager
service manual (Publication No. 81-370-8105) install the roof rack crossrail and stanchion
assemblies.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-06-10-91 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Roof and Associated Components > Roof Rack Frame > Component
Information > Technical Service Bulletins > All Technical Service Bulletins for Roof Rack Frame: > 23-14-98 > Apr > 98 >
Roof Rack - Rattles at Highway Speeds
Roof Rack Frame: All Technical Service Bulletins Roof Rack - Rattles at Highway Speeds
NO: 23-14-98
GROUP: Body
DATE: Apr. 24, 1998
SUBJECT: Roof Rack Rattles At Highway Speeds
MODELS: 1996 - 1998 (NS) Town & Country/Caravan/Voyager
SYMPTOM/CONDITION: Roof rack rattles at speeds above 65 mph (105 kph). The rattle may be
heard at slower vehicle speeds when operating the vehicle in strong crosswinds or headwinds.
Rough road surfaces DO NOT have an effect on this condition.
DIAGNOSIS: If the vehicle operator describes the above condition, perform the Repair Procedure.
PARTS REQUIRED:
REPAIR PROCEDURE: This bulletin involves installing revised roof rack crossrails.
1. Using the procedure outlined on page 23-51 of the 1998 Town & Country, Caravan and Voyager
service manual (Publication No. 81-370-8105) remove the roof rack crossrail and stanchion
assemblies.
2. Separate the stanchions from the crossrails and discard the crossrails.
3. Install the stanchions onto the revised crossrails.
4. Using the procedure outlined on page 23-52 of the 1998 Town & Country, Caravan and Voyager
service manual (Publication No. 81-370-8105) install the roof rack crossrail and stanchion
assemblies.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-06-10-91 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time
Child Seat: Technical Service Bulletins Child Seat - Tether Anchor Part Numbers & Labor Time
NUMBER: 23-008-00 Rev. B
GROUP: Body
DATE: Nov. 24, 2000
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-08-00 REV. A, DATED
JULY 7, 2000, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODELS AND PARTS.
SUBJECT: Child Seat Tether Anchors
MODELS: 1989 - 1995
(AA) Spirit/Acclaim/LeBaron Sedan
1989 - 2000 (AB) Ram Van/Wagon
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1989 - 1994 (AG) Daytona
1989 (AH) Lancer/Lebaron GTS
1989 - 1993 (AJ) Lebaron Coupe
1989 - 1990 (AK) Aries/Reliant
1989 - 1990 (AL) Horizon/Omni
1989 (AM) Diplomat/Gran Fury/New Yorker Fifth Avenue
1989 - 2000 (AN) Dakota
1989 - 1994 (AP) Shadow/Sundance
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1988 - 1992 (BB) Monaco/Premier
1990 - 1994 (BD) Laser/Talon
1994 - 2001 (BR/BE) Ram Truck
1989 - 1992 (B2) Colt/Summit
1992 - 1995 (B3) Colt Vista
1989 (B5) Conquest
1989 - 1995 (B7) Stealth (2000 GTX Dodge/Eagle, Canada)
1992 - 1995 (B8) Colt Vista Wagon/Summit Wagon
1993 - 1994 (B9) Colt/Summit
1998 - 2000 (DN) Durango
1995 - 1999 (FJ) Sebring/Avenger/Talon
1995 - 1999 JA Cirrus/Stratus/Breeze
1993 - 1999 (LH) Concorde/Intrepid/Vision/LHS/New Yorker/300M
1996 - 2000 (NS) Town & Country/Caravan/Voyager
1995 - 2000 (PL) Neon
1997 - 1999 (PR) Prowler
1996 - 1999 (SR) Viper/Viper GTS
**2000 (TJ) Wrangler**
1999 - 2000 (WJ) Grand Cherokee
1989 - **2000** (XJ) Cherokee/Wagoneer
1993 - 1998 (WJ) Grand Cherokee/Grand Wagoneer
NOTE:
THIS BULLETIN IS PROVIDED TO IDENTIFY THE PARTS AND LABOR OPERATION
NUMBERS NECESSARY TO INSTALL A CHILD SEAT TETHER ANCHOR. DAIMLERCHRYSLER
WILL REIMBURSE YOU FOR THE ANCHORS AND LABOR TO INSTALL THEM. THIS IS BEING
DONE IN THE INTEREST OF CUSTOMER SATISFACTION. REFER TO GLOBAL WARRANTY
ADMINISTRATION BULLETIN # D-99-23 FOR COMPLETE REIMBURSEMENT INSTRUCTIONS.
DISCUSSION: User-ready child restraint tether strap anchors will be provided in passenger cars in
the 2000 Model Year, and in light trucks in the 2001 Model Year. Tether straps improve the
performance of child restraints in collisions. Because of the publicity that has accompanied the "Fit
for a Kid" Program, owners of earlier products are expected to approach dealers for the free
provision and installation of the anchor hardware. DaimlerChrysler Corporation is offering child seat
tether anchors for the selected vehicles listed above. Each tether anchor is packaged in a kit
containing all necessary parts and a detailed instruction sheet.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8137
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8138
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8139
PARTS REQUIRED:
POLICY: Customer Satisfaction
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8140
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Child Seat > Component Information > Technical Service Bulletins
> Child Seat - Tether Anchor Part Numbers & Labor Time > Page 8141
TIME ALLOWANCE:
FAILURE CODE:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Description and Operation
Seat Memory Switch: Description and Operation
SYSTEM OPERATION
Memory Selector Switches The memory selector switches are mounted on the driver's door trim
panel within easy reach of the driver. They provide a means to set or recall either of two positions
of seat and recliner, and the side view mirrors as chosen by the driver.
The inputs from these switches to the memory seat/mirror module is a ground level signal. 1.
Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and
release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press
any switches for 10 seconds. 4. To program the second driver's position, follow the above
sequence. 5. To recall either of the programmed positions momentarily press and release either
memory selector switch 1 or 2.
Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing
requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum
hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must
be met for proper operation of the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Description and Operation > Page 8146
Seat Memory Switch: Testing and Inspection
To test the memory selector switch:
1. Remove the memory selector switch. Refer to removal procedure.
Memory Selector Switch Continuity
2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Memory Positioning Systems > Seat Memory Switch > Component
Information > Description and Operation > Page 8147
Seat Memory Switch: Service and Repair
REMOVAL
1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel.
2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Control Module > Component Information > Technical
Service Bulletins > Memory Power Seat - Travel Range
Power Seat Control Module: Technical Service Bulletins Memory Power Seat - Travel Range
NO: 08-44-98
GROUP: Electrical
DATE: Dec. 11, 1998
SUBJECT: Memory Power Seat Travel Range
MODELS:
1996-1999 (NS) Town & Country 1996-1999 (GS) Chrysler Voyager 1996-1998 (ZJ) Grand
Cherokee 1996-1998 (ZG) Grand Cherokee (International Market)
DISCUSSION:
The Memory Seat/Mirror Module (MSMM) (on ZJ/ZG the module is for the seat only) detects and
remembers where the end of seat travel (called "soft stop") is in each direction. A soft stop is set in
MSMM memory when the position sensing feedback voltage, controlled by a potentiometer on the
motor end, fails to change. The feedback voltage potentiometers vary the position sensing
feedback voltage based on seat position/movement (no movement, no change in position sensing
feedback voltage). The seat motor automatically stops at the soft stop on any subsequent
movement so the motor does not run into a stall condition (end of travel).
The soft stop limits will be updated any time the MSMM senses a mechanical stall (such as when
something is stuck under or behind the seat that causes the seat to stop moving). These soft stops
can prevent the seat from being able to have memory positions set over the full range of travel.
Also, positions that were previously programmed to locations beyond an updated soft stop limit will
not be recalled as they are "out of range."
When a new MSMM or seat track is installed into a vehicle, the soft stops must be programmed
into the MSMM memory for proper operation, the last paragraph of this TSB explains the procedure
to properly set soft stops. Failure to properly set soft stops could result in intermittent memory seat
operation.
There are two potential reasons for intermittent memory functioning of the seats. The first
possibility is the soft stops learned by the MSMM may need to be reset. New soft stops are learned
by the MSMM any time movement is restricted. (This could be as simple as hitting an obstruction in
the seat's path or a person shifting their body while a power seat motor is in operation.)
The second reason only applies to NS/GS-vehicles, intermittent operation of the memory seat can
be caused by a poor connection at pin 23 of the P34 connector which is located near the right side
of the steering column. This circuit is used to communicate and control the seat module. This circuit
"locks out" movement when the vehicle is not in park and also causes seat position recall when
used with the Remote Keyless Entry (RKE) feature. The P34 connector should be inspected for
fully seated and clean contacts.
To check and reset the soft stop limits in memory, use the control switches on the side of the seat
to move the seat in one direction to the end of travel, then energize the seat again in the same
direction until it stops and for three additional seconds after it stops. The amount that the seat
moved upon the second energizing is the amount the soft stop has been reprogrammed. Repeat
this procedure for each of the directions of movement (one at a time).
NOTE:
IF THE SEAT TRACK ASSEMBLY OR MSMM HAVE NOT BEEN REPLACED, THIS METHOD OF
SOFT STOP RESET LEAVES THE CUSTOMER'S SETTINGS PROGRAMMED IN THE MSMM
(AS OPPOSED TO USING DIAGNOSTIC MODES 1 AND 2 DESCRIBED IN THE SERVICE
MANUAL).
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Motor > Component Information > Testing and
Inspection
Power Seat Motor: Testing and Inspection
1. Remove power seat switch from seat 2. Disconnect wire connector. 3. Using a voltmeter check
for battery voltage at Pin 5. Using an ohmmeter, check Pin 1 for ground.
Seat Motor Test
4. To test the seat motors, refer to and verify proper seat responses. Using two jumper wires,
connect one to a battery supply and the other to a
ground. Connect the other ends to the seat wire harness connector as described. If any motor fails
to operate, check wire connectors to the motor. If not OK, repair as necessary If OK, replace seat
motor/track assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and
Operation
Power Seat Switch: Description and Operation
SYSTEM OPERATION
Seat and Recliner Switches The seat and recliner switch assembly is mounted outboard on the
seat side-shield. Press and hold the desired seat or recliner switch to effect movement. The
Memory Seat/Mirror Module (MSM Module) will drive a maximum of 2 motors at a time in a given
direction. If conflicting directions are requested, the priority for response will be as follows: Seat Track Rearward
- Seat Front Down
- Seat Rear Down
- Recliner Rearward
- Seat Track Forward
- Seat Front Up
- Seat Rear Up
- Recliner Forward
The inputs from these switches to the MSM Module is a current limited battery source fed by the
MSM Module. This protects the MSM Module printed circuit board traces from acting as fuses. All
of these switch contact inputs to the module are normally closed to ground, except when actuated.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Power Seat Switch > Component Information > Description and
Operation > Page 8158
Power Seat Switch: Testing and Inspection
1. Remove power seat switch from seat.
Power Seat Switch Test
2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the
switch positions, replace switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> Customer Interest: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise
Seat Back: Customer Interest Driver's Side Seat Back - Creak Noise
NO:23-69-97
GROUP: Body
DATE: Dec. 19, 1997
SUBJECT: Seat Back Creak Noise - Driver's Side
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ADJUSTABLE LUMBAR DRIVER'S
SEAT.
SYMPTOM/CONDITION: A creaking sound is heard when pressure is applied to and removed from
the lumbar area of the driver's seat.
DIAGNOSIS: Actuate the lumbar adjustment to the fully extended position. Apply pressure to the
front of the seat back in the lumbar area and listen for a creaking noise. If a creaking noise is
heard, perform the Repair Procedure.
PARTS REQUIRED:
AR (1) 0SF471C3AA Back, Seat - (Trim Code H7 or E5) Gray
AR (1) 0SF471K5AA Back, Seat - (Trim Code H7 or E5) Camel
AR (1) 0SF471JKAA Back, Seat - (Trim Code H7 or E5) Silver Fern
AR (1) 0SF491C3AA Back, Seat - (Trim Code XL) Gray
AR (1) 0SF491K5AA Back, Seat - (Trim Code XL) Camel
AR (1) 0SF511C3AA Back, Seat - (Trim Code XL Heated) Gray
AR (1) 0SF511K5AA Back, Seat - (Trim Code XL Heated) Camel
AR (1) 0SF531C3AA Back, Seat - (Trim Code FL) Gray
AR (1) 0SF531K5AA Back, Seat - (Trim Code FL) Camel
REPAIR PROCEDURE: This bulletin involves replacing the driver's seat back.
1. Remove the driver's seat headrest.
2. Remove the armrest.
3. Remove the seat back recliner lever.
4. Remove the lumbar adjustment lever.
5. Remove both seat cushion side covers.
6. Remove nut attaching the recliner to the seat back frame.
7. Remove both pivot bolts and separate the seat back from the recliner.
8. Place the mounting stud of the revised seat back (specified in the Parts Required section) into
the recliner.
9. Install the pivot bolts and torque to 30-50 ft. lbs. (41-67 Nm).
10. Install the nut attaching the recliner to the seat back frame and torque to 85-125 in. lbs. (10-14
Nm).
11. Install both seat cushion side covers.
12. Install the lumbar adjustment lever.
13. Install the seat back recliner lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> Customer Interest: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise > Page 8167
14. Install the armrest.
15. Install the driver's seat headrest.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-20-32-96 0.6 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise
Seat Back: All Technical Service Bulletins Driver's Side Seat Back - Creak Noise
NO:23-69-97
GROUP: Body
DATE: Dec. 19, 1997
SUBJECT: Seat Back Creak Noise - Driver's Side
MODELS: 1998 (NS) Town & Country/Caravan/Voyager
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH ADJUSTABLE LUMBAR DRIVER'S
SEAT.
SYMPTOM/CONDITION: A creaking sound is heard when pressure is applied to and removed from
the lumbar area of the driver's seat.
DIAGNOSIS: Actuate the lumbar adjustment to the fully extended position. Apply pressure to the
front of the seat back in the lumbar area and listen for a creaking noise. If a creaking noise is
heard, perform the Repair Procedure.
PARTS REQUIRED:
AR (1) 0SF471C3AA Back, Seat - (Trim Code H7 or E5) Gray
AR (1) 0SF471K5AA Back, Seat - (Trim Code H7 or E5) Camel
AR (1) 0SF471JKAA Back, Seat - (Trim Code H7 or E5) Silver Fern
AR (1) 0SF491C3AA Back, Seat - (Trim Code XL) Gray
AR (1) 0SF491K5AA Back, Seat - (Trim Code XL) Camel
AR (1) 0SF511C3AA Back, Seat - (Trim Code XL Heated) Gray
AR (1) 0SF511K5AA Back, Seat - (Trim Code XL Heated) Camel
AR (1) 0SF531C3AA Back, Seat - (Trim Code FL) Gray
AR (1) 0SF531K5AA Back, Seat - (Trim Code FL) Camel
REPAIR PROCEDURE: This bulletin involves replacing the driver's seat back.
1. Remove the driver's seat headrest.
2. Remove the armrest.
3. Remove the seat back recliner lever.
4. Remove the lumbar adjustment lever.
5. Remove both seat cushion side covers.
6. Remove nut attaching the recliner to the seat back frame.
7. Remove both pivot bolts and separate the seat back from the recliner.
8. Place the mounting stud of the revised seat back (specified in the Parts Required section) into
the recliner.
9. Install the pivot bolts and torque to 30-50 ft. lbs. (41-67 Nm).
10. Install the nut attaching the recliner to the seat back frame and torque to 85-125 in. lbs. (10-14
Nm).
11. Install both seat cushion side covers.
12. Install the lumbar adjustment lever.
13. Install the seat back recliner lever.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> All Technical Service Bulletins: > 23-69-97 > Dec > 97 > Driver's Side Seat Back - Creak Noise > Page 8173
14. Install the armrest.
15. Install the driver's seat headrest.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-20-32-96 0.6 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Back > Component Information > Technical Service Bulletins
> All Other Service Bulletins for Seat Back: > 08-39-97 > Nov > 97 > RKE Transmitter - Premature Battery Failure
Keyless Entry Transmitter Battery: All Technical Service Bulletins RKE Transmitter - Premature
Battery Failure
NO: 08-39-97
GROUP: Electrical
DATE: Nov. 28, 1997
SUBJECT: Remote Keyless Entry Transmitter Batteries Discharge Prematurely
MODELS:
1997 - 1998 (AB) Ram Van/Wagon
1997 - 1998 (AN) Dakota/Dakota Cab & Chassis
1998 (BRIBE)Ram Truck
1998 (DN) Durango
1997 (LH) Concorde/Intrepid/LHS/Vision
1997 - 1998 (NS) Town & Country/Caravan/Voyager
1997 - 1998 (PL) Neon
1997 (PR) Prowler
1997 - 1998 (ZJ) Grand Cherokee
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO AUGUST 15, 1997 (MDH 0815XX).
SYMPTOM/CONDITION:
Remote Keyless Entry (RKE) transmitter batteries discharge in approximately 6 weeks.
DIAGNOSIS:
If the vehicle operator describes the Symptom/Condition and the vehicle was built prior to MDH
0815XX, perform the Repair Procedure.
PARTS REQUIRED:
AR 04686366 Transmitter, RKE- NS, PL & PR
AR 04759136AB Transmitter, RKE- LH
AR 56007049 Transmitter, RKE- AB & 1997 AN
AR 56008761 Transmitter 1, RKE- ZJ & DN
AR 56008762 Transmitter 2, RKE- ZJ
AR 56021903AA Transmitter, RKE- BR/BE & 1998 AN
REPAIR PROCEDURE:
This bulletin involves replacing the RKE transmitter(s).
1. Replace RKE transmitter(s) that have discharged batteries.
2. Program the RKE transmitter(s) to the vehicle.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-80-28-93 0.2 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions
Seat Heater: Technical Service Bulletins Interior - Seat Heater Service Manual Revisions
NUMBER: 26-04-98C
GROUP: Miscellaneous
DATE: April, 1998
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
MODELS: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-8105
DESCRIPTION OF CHANGES
Revisions to the electrically heated Systems section
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8188
8N-1
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8189
8N-2
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8190
8N-3
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8191
8N-4
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8192
8N-5
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8193
8N-6
POLICY: Information Only
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8194
Seat Heater: Technical Service Bulletins Interior - Seat Heater Harness Location Revision
NUMBER: 26-04-99G
GROUP: Miscellaneous
DATE: April, 1999
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Caravan, Voyager, Town & Country Service Manual - Publication Number
81-370-8105
DESCRIPTION OF CHANGES
Revision to the Electrically Heated Seat harness location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Interior - Seat Heater Service Manual Revisions > Page 8195
8N-4
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Technical Service
Bulletins > Page 8196
Seat Heater: Description and Operation
The content of this article reflects the changes called out by TSB 26-04-99.
INTRODUCTION
Individually controlled electrically heated front seats are available factory-installed optional
equipment. The seat heaters will only operate when the ignition switch is in the On position, and
the surface temperature at the front seat heating element sensors is below the designed
temperature set points of the system. The heated seat system will not operate in ambient
temperatures greater than about 32 °C (90 °F).
There are separate three-position switches for each front seat located in the inboard seat cushion
side shield. An Off, Low, or High position can be selected with each switch, and Light-Emitting
Diodes (LED) for each switch illuminate to give a visual indication that the system is turned on. The
Low heat position set point is about 32 °C (90 °F), and the High heat position set point is about 38
°C (100 °F). Each switch controls a Heated Seat Control Module (HSCM) mounted to the seat
cushion frame under each front seat.
When a seat heater is turned on, a sensor located near the seat cushion electric heater element
provides the HSCM with an input indicating the surface temperature of the seat cushion. If the
surface temperature input is below the temperature set point for the selected Low or High switch
position, a relay within the HSCM energizes the heating elements in the seat cushion and back.
When the sensor input indicates the correct temperature set point has been achieved, the HSCM
de-energizes the relay The HSCM will continue to cycle the relay as needed to maintain the
temperature set point.
The HSCM will automatically turn off the heating elements if it detects an open in the sensor circuit,
or a short in the heating element circuit causing an excessive current draw. The system is also
turned off automatically when the ignition switch is turned to the Off position. The control circuit
operates on ignition switched battery feed through a fuse in the junction block. The heating
elements operate on battery feed supplied through the power seat circuit breaker located in the
wire harness under the driver's seat.
SYSTEM OPERATION
Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat,
one for the seat cushion and the other for the seat back. The two element for each seat are
connected in series with the HSCM.
The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature
sensor is used for each seat, and it is integrated into the seat cushion heating element.
The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which
are serviced individually. The heating elements and temperature sensor cannot be repaired and, if
faulty or damaged, the affected seat cover assembly must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection >
Heated Seat System
Seat Heater: Testing and Inspection Heated Seat System
Before testing the individual components in the heated seat system, check the following:
- If the heated seat switch LED doesn't light with the ignition switch in the On position and the
heated seat switch in the Low or High position, check the fuse in the junction block. If the Fuse is
OK, test the heated seat switch as described. If not OK, repair the shorted circuit or component as
required and replace the faulty fuse.
- If the heated seat switch LED lights, but the heating elements don't heat, check the circuit breaker
in the junction block. If the circuit breaker is OK, test the heated seat elements as described. If not
OK, replace the faulty circuit breaker.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater > Component Information > Testing and Inspection >
Heated Seat System > Page 8199
Seat Heater: Testing and Inspection Heated Seat Element
The wire harness connectors for the seat cushion and seat back heating elements are located
under the seat, near the rear edge of the seat cushion frame.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Description and Operation
Seat Heater Control Module: Description and Operation
SYSTEM OPERATION
The Heated Seat Control Module (HSCM) is an electronic thermostatic module designed to operate
the electric seat heater elements. Two modules are used in the vehicle, one for each front seat.
The HSCM for each seat is installed on front portion of each cushion pan. The wire harness
connector is secured by an integral clip to the inside surface of the outboard seat cushion frame.
Inputs to the module include the resistor multiplexed seat switch signal (which includes the seat
cushion temperature sensor circuits), an ignition-switched battery feed, a non-switched battery
feed, and a ground. The only HSCM output is the feed for the seat heating elements.
The HSCM cannot be repaired and, if faulty or damaged, it must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Description and Operation > Page 8203
Seat Heater Control Module: Testing and Inspection
Before testing the heated seat control module, test the heated seat switch, the heated seat
elements, and the heated seat sensor as described. If testing of the heated seat switch, elements,
and sensor reveals no problems, proceed as follows.
1. Replace the heated seat control module with a known good unit and test the operation of the
heated seats. If OK, discard the faulty heated seat
control module. If not OK, go to Step 2.
2. Test each of the circuits from the heated seat switch, heated seat elements, and heated seat
sensor to the heated seat control module. Repair any
short or open circuits as required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Control Module > Component Information >
Description and Operation > Page 8204
Seat Heater Control Module: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Remove the seat assembly from the
vehicle. 3. With seat upside down on bench, remove the wiring harness connector from the
module. 4. Remove the screws securing the (HSCM) to the underside of the seat cushion pan. 5.
Remove module from seat cushion pan.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and
Operation
Seat Heater Switch: Description and Operation
SYSTEM OPERATION
The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The
two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective
Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both
the driver and the front seat passenger can select a preferred seat heating mode.
Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat
that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If
either switch or LED is faulty, the switch must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and
Operation > Page 8208
Seat Heater Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion
side cover. Check for continuity between the ground circuit cavity of the switch wire harness
connector
and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit
as required.
3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position,
disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open
circuit as required.
4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK,
replace the faulty switch.
5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Switch > Component Information > Description and
Operation > Page 8209
Seat Heater Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755),
gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect
wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out
switch from rear of switch bezel. 5. Remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description
and Operation
Seat Heater Thermostat: Description and Operation
SYSTEM OPERATION
Heated Seat Element And Sensor Two heated seat heating elements are used in each front seat,
one for the seat cushion and the other for the seat back. The two element for each seat are
connected in series with the HSCM.
The temperature sensor is a Negative Temperature Coefficient (NTC) thermistor. One temperature
sensor is used for each seat, and it is integrated into the seat cushion heating element.
The heating elements are sewn into the seat cushion cover and seat back cover assemblies, which
are serviced individually. The heating elements and temperature sensor cannot be repaired and, if
faulty or damaged, the affected seat cover assembly must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Heater Thermostat > Component Information > Description
and Operation > Page 8213
Seat Heater Thermostat: Testing and Inspection
The wire harness connector for the seat cushion heating element and sensor are located under the
seat, near the rear edge of the seat cushion frame.
1. Disconnect and isolate the battery negative cable. Unplug the 4-way heated seat cushion wire
harness connector. 2. Using an ohmmeter, check the resistance between the heated seat switch
output circuit cavity and the ground circuit cavity of the seat cushion
cover half of the heated seat cushion wire harness connector. The sensor resistance should be
between 2 kilo ohms and 200 kilo ohms. If OK, test the heated seat control module as described. If
not OK, replace the faulty seat cushion cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles
Seat Latch: Customer Interest Quad Seat Easy Entry Latch - Rattles
NUMBER: 23-27-99
GROUP: Body
DATE: Jul. 23, 1999
SUBJECT: Quad Seat Easy Entry Latch Rattle
OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: Rattle noise is heard when driving
DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry
latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure.
PARTS REQUIRED:
1 04773968 Tape, Flock
1 04318063 Grease
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the mylar tape from the easy entry latch striker (Fig. 1)
2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with
isopropyl alcohol.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> Customer Interest for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 8222
3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2).
4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker.
5. Return the quad seat to its latched/normal position.
6. Repeat for the other quad seat.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles
Seat Latch: All Technical Service Bulletins Quad Seat Easy Entry Latch - Rattles
NUMBER: 23-27-99
GROUP: Body
DATE: Jul. 23, 1999
SUBJECT: Quad Seat Easy Entry Latch Rattle
OVERVIEW: This bulletin involves installing flock tape and grease to the quad seat latch.
MODELS:
1996 - 1999 (NS) Town & Country/Caravan/Voyager 1996 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: Rattle noise is heard when driving
DIAGNOSIS: Release the easy entry latch and tilt the quad seats forward. Inspect the easy entry
latch striker for damaged mylar tape. If the tape is damaged, perform the Repair Procedure.
PARTS REQUIRED:
1 04773968 Tape, Flock
1 04318063 Grease
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the mylar tape from the easy entry latch striker (Fig. 1)
2. Clean the inside surface of the easy entry latch hook and the easy entry latch striker with
isopropyl alcohol.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Seats > Seat Latch > Component Information > Technical Service Bulletins
> All Technical Service Bulletins for Seat Latch: > 23-27-99 > Jul > 99 > Quad Seat Easy Entry Latch - Rattles > Page 8228
3. Apply flocked tape, p/n 04773968, to the inside surface of the easy entry latch hook (Fig 2).
4. Apply a thin coat of grease, p/n 04318063, to the easy entry latch striker.
5. Return the quad seat to its latched/normal position.
6. Repeat for the other quad seat.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-41-64-93 Apply Tape and Grease to Both Seats 0.2 Hrs.
FAILURE CODE: AM - Authorized Modification
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Hood Switch / Sensor > Hood
Sensor/Switch (For Alarm) > Component Information > Service and Repair
Hood Sensor/Switch (For Alarm): Service and Repair
REMOVAL
1. Release the hood latch and open the hood. 2. Using a small flat blade screws driver, try trigger
switch from top of the radiator closure panel.
Hood Ajar Switch
3. Disconnect the trigger switch from the wire connector and remove the switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Door Lock Switch >
Component Information > Testing and Inspection
Power Door Lock Switch: Testing and Inspection
1. Remove door lock switch bezel assembly from door. 2. Disconnect wire connector from back of
door lock switch. 3. Depress switch to LOCK position.
Door Lock Switch
4. Using an ohmmeter, test switch resistance between Pins 2 and 3. 5. Depress switch to UNLOCK
position. 6. Test resistance between Pins 2 and 3. 7. If resistance values are not within the
parameters shown replace the door lock switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Diagrams
Power Mirror/Window Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Testing and Inspection > Mirror Switch Test
Power Mirror Switch: Testing and Inspection Mirror Switch Test
1. Remove power mirror switch from mounting position. 2. Disconnect wiring harness at switch
connector.
Mirror Switch Test
3. Using a ohmmeter, test for continuity between the terminals of the switch as shown in the Mirror
Switch Continuity Chart. 4. If results shown in the chart are not obtained, replace the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Testing and Inspection > Mirror Switch Test > Page 8242
Power Mirror Switch: Testing and Inspection Side View Mirror Switch Stuck
The mirror switches in the instrument panel have normally open contacts when in their inactive
state. The left/right rocker switch has a center-off detent. If this switch is actuated to either side, it
then becomes connected to the P73/P70, circuits which are the mirror motor common connections.
No faults will result from this action by itself. If one of the other switch contacts from the round
portion of the switch becomes accidentally closed, It can cause problems such as both mirrors
operating at the same time in the vertical or horizontal modes.
Turn ignition switch ON: If two mirror switch contacts, from the round portion, are stuck in the
closed position, and the left/right portion is actuated to either side, a mirror motor will become
actuated. This will drive the motor to its stop, where it will keep ratcheting until a switch contact is
released or the ignition is turned to OFF. Replace the mirror switch assembly to correct this
condition.
- With the ignition switch in the ON or the OFF position: If only one mirror switch contact is stuck in
the closed position, the mirror motor will not become actuated. During an ignition switch recall of a
driver 5 chosen position, the Memory Seat/Mirror Module will attempt to drive the mirror motor only
if:
- The closed switch contact was the same as the desired direction
- Until the lack of a signal seen by the module shuts off the drive to the motor
The Memory Seat/Mirror Module will shut off the drive to the desired motor. It is possible that a
single stuck contact could place an opposite mirror or direction into a series connection. This would
run the connected motors at approximately half speed. Replace the mirror switch assembly to
correct this condition.
Mirror Mechanization
Mirror Mechanization Table
The 25-way connector at the Memory Seat/Mirror Module (under the driver's seat) and the mirror
mechanization show that both mirrors use the same functions. The rheostat for position sensing
utilizes the wire from the module to the mirror as both feed and sense line on the same wires, D
and F. The ground return wire, E, stands alone.
The mirror motors for each side use a common connection, B, which becomes automatically
connected to the proper polarity power connection during either manual (through the mirror switch)
or recall (through the Memory Seat/Mirror Module) modes of operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch
Power Mirror Switch: Service and Repair Power Mirror Switch
Power Mirror Switch
REMOVAL
1. Remove instrument cluster bezel. 2. Disconnect wire connector from back of power mirror
switch. 3. Disengage lock tabs above and below the mirror switch. 4. Pull power mirror switch from
headlamp switch bezel. 5. Remove power mirror switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Mirror Switch >
Component Information > Service and Repair > Power Mirror Switch > Page 8245
Power Mirror Switch: Service and Repair Power Mirror Switch Lamp
Power Mirror Switch Lamp
REMOVAL
1. Remove instrument cluster bezel. 2. Rotate bulb socket counter clockwise one quarter turn. 3.
Pull bulb socket from back of power mirror switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Description and Operation
Power Seat Switch: Description and Operation
SYSTEM OPERATION
Seat and Recliner Switches The seat and recliner switch assembly is mounted outboard on the
seat side-shield. Press and hold the desired seat or recliner switch to effect movement. The
Memory Seat/Mirror Module (MSM Module) will drive a maximum of 2 motors at a time in a given
direction. If conflicting directions are requested, the priority for response will be as follows: Seat Track Rearward
- Seat Front Down
- Seat Rear Down
- Recliner Rearward
- Seat Track Forward
- Seat Front Up
- Seat Rear Up
- Recliner Forward
The inputs from these switches to the MSM Module is a current limited battery source fed by the
MSM Module. This protects the MSM Module printed circuit board traces from acting as fuses. All
of these switch contact inputs to the module are normally closed to ground, except when actuated.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Power Seat Switch >
Component Information > Description and Operation > Page 8249
Power Seat Switch: Testing and Inspection
1. Remove power seat switch from seat.
Power Seat Switch Test
2. Using an ohmmeter, perform the switch continuity tests. If there is no continuity at any of the
switch positions, replace switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation
Seat Heater Switch: Description and Operation
SYSTEM OPERATION
The heated seat switch is mounted on the inboard seat cushion side shield of each front seat. The
two switches, one switch for each front seat, provide a resistor multiplexed signal to their respective
Heated Seat Control Module (HSCM). Each switch has an Off, Low, and High position so that both
the driver and the front seat passenger can select a preferred seat heating mode.
Each switch has a Light-Emitting Diode (LED), which lights to indicate that the heater for the seat
that the switch controls is turned on. The heated seat switches and their LED cannot be repaired. If
either switch or LED is faulty, the switch must be replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 8253
Seat Heater Switch: Testing and Inspection
1. Disconnect and isolate the battery negative cable. 2. Remove the switch from the seat cushion
side cover. Check for continuity between the ground circuit cavity of the switch wire harness
connector
and a good ground. There should be continuity If OK, go to Step 3. If not OK, repair the open circuit
as required.
3. Connect the battery negative cable. Turn the ignition switch to the On position. Check for battery
voltage at the fused ignition switch output circuit
cavity of the switch wire harness connector. If OK, turn the ignition switch to the Off position,
disconnect and isolate the battery negative cable, and go to Step 4. If not OK, repair the open
circuit as required.
4. Move the heated seat switch to the Low position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 280 ohms. If OK, go to Step 5. If not OK,
replace the faulty switch.
5. Move the heated seat switches to the High position. Using an ohmmeter, check the resistance
between the fused ignition switch output circuit
terminal and the heated seat switch output circuit terminal in the connector receptacle on the back
of the switch. The resistance reading should be about 487 ohms. If not OK, replace the faulty
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Heater Switch >
Component Information > Description and Operation > Page 8254
Seat Heater Switch: Service and Repair
REMOVAL
1. Disconnect and isolate the battery negative cable. 2. Using a trim stick, (special tool #C-4755),
gently pry up on switch bezel and pull switch bezel from seat cushion side cover. 3. Disconnect
wire harness connector from back side of heated seat switch. 4. Using a trim stick, gently pry out
switch from rear of switch bezel. 5. Remove switch from bezel.
INSTALLATION
For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Description and Operation
Seat Memory Switch: Description and Operation
SYSTEM OPERATION
Memory Selector Switches The memory selector switches are mounted on the driver's door trim
panel within easy reach of the driver. They provide a means to set or recall either of two positions
of seat and recliner, and the side view mirrors as chosen by the driver.
The inputs from these switches to the memory seat/mirror module is a ground level signal. 1.
Adjust the seat, recliner and side view mirrors to the desired position. 2. Press momentarily and
release memory switch S. 3. Press momentarily and release memory switch 1 or 2. Do NOT press
any switches for 10 seconds. 4. To program the second driver's position, follow the above
sequence. 5. To recall either of the programmed positions momentarily press and release either
memory selector switch 1 or 2.
Definition Of: Momentarily And Release The memory seat/mirror module has switch input timing
requirements of a minimum press momentarily time of 250 milliseconds followed by a maximum
hold time of 5 seconds, followed by a maximum release time between steps of 5 seconds that must
be met for proper operation of the system.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Description and Operation > Page 8258
Seat Memory Switch: Testing and Inspection
To test the memory selector switch:
1. Remove the memory selector switch. Refer to removal procedure.
Memory Selector Switch Continuity
2. Using an ohmmeter check continuity reading between switch pins. Refer for proper Pin numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Sensors and Switches - Body and Frame > Seat Memory Switch >
Component Information > Description and Operation > Page 8259
Seat Memory Switch: Service and Repair
REMOVAL
1. Insert a proper tool through the access slot located at the front forward edge of the switch bezel.
2. Pry the switch out from the door trim panel opening. 3. Disconnect wire connector from back of
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion
Strut / Shock Tower: Customer Interest Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > Customer Interest for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower Corrosion >
Page 8268
TIME ALLOWANCE
FAILURE CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower
Corrosion
Strut / Shock Tower: All Technical Service Bulletins Suspension/Body - Strut Tower Corrosion
NUMBER: 23-044-02
GROUP: Body
DATE: Oct. 14, 2002
SUBJECT: NS Strut Tower Corrosion
OVERVIEW: This bulletin involves correcting a corrosion staining, surface corrosion, or corrosion
perforation condition at the top of the strut tower/s.
MODELS: 1996 - 2000 NS Town&Country;/Voyager/Caravan
SYMPTOM/CONDITION: Cosmetic corrosion or perforation at upper strut tower/s usually between
the strut and upper load path beam inner panel (inner fender).
DIAGNOSIS: Inspect left and right strut towers for condition. If corrosion is present, perform one of
the following repair procedures.
NOTE:
ANY UNDER HOOD LABELS REQUIRING REPLACEMENT DURING THESE REPAIRS SHOULD
BE OBTAINED PRIOR TO BEGINNING REPAIRS.
PARTS/MATERIALS REQUIRED
EQUIPMENT REQUIRED
REPAIR DESCRIPTION:
Repair A - Cosmetic corrosion removal and the application of corrosion resistant materials and/or
primers and topcoats.
Repair B - Corrosion perforation removal and installation of 1 or 2 new cap/s and kit/s.
NOTE:
REPAIR PROCEDURES ARE OUTLINED IN THE INSTRUCTION SHEET INCLUDED IN THE
PARTS KITS.
POLICY: Reimbursable within the provisions of the warranty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Strut / Shock Tower > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Strut / Shock Tower: > 23-044-02 > Oct > 02 > Suspension/Body - Strut Tower
Corrosion > Page 8274
TIME ALLOWANCE
FAILURE CODE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8284
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8285
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8286
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
Customer Interest for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor > Page 8287
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor >
Page 8293
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor >
Page 8294
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor >
Page 8295
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Unibody > Cowl > Component Information > Technical Service Bulletins >
All Technical Service Bulletins for Cowl: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor >
Page 8296
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins > All
Technical Service Bulletins for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange
Weatherstrip: All Technical Service Bulletins Door Weatherstrip - Falls Off Mounting Flange
NO: 23-34-98
GROUP: Body
DATE: Aug. 7, 1998
SUBJECT: Front Door Body Mounted Weatherstrip Retention
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION:
The front door body mounted weatherstrip falls off mounting flange, usually along the top of the
door opening.
DIAGNOSIS:
Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or
pulls off easily, perform the Repair Procedure.
NOTE:
THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP
IS REMOVED FOR ANY REASON.
PARTS REQUIRED:
AR NPN Isopropyl Alcohol
REPAIR PROCEDURE:
This bulletin involves removing the slip coating on the weatherstrip and mounting flange.
1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the
upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the
weatherstrip installed.
2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the
seal mounts to.
3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that
mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as
possible without bending it open. If done properly, there will be some black residue on the rag from
the weatherstrip.
4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure.
5. Reinstall the weatherstrip on the flange, make sure it is fully seated.
6. Repeat steps 1 through 5 for the other side.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-51-09-92 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Body and Frame > Weatherstrip > Component Information > Technical Service Bulletins >
Customer Interest for Weatherstrip: > 23-34-98 > Aug > 98 > Door Weatherstrip - Falls Off Mounting Flange
Weatherstrip: Customer Interest Door Weatherstrip - Falls Off Mounting Flange
NO: 23-34-98
GROUP: Body
DATE: Aug. 7, 1998
SUBJECT: Front Door Body Mounted Weatherstrip Retention
MODELS: 1998 - 1999 (NS) Town & Country/Caravan/Voyager 1998 - 1999 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION:
The front door body mounted weatherstrip falls off mounting flange, usually along the top of the
door opening.
DIAGNOSIS:
Open the door and visually inspect the weatherstrip on the body. If it is off the mounting flange or
pulls off easily, perform the Repair Procedure.
NOTE:
THIS REPAIR PROCEDURE IS ALSO REQUIRED IF THE BODY MOUNTED WEATHERSTRIP
IS REMOVED FOR ANY REASON.
PARTS REQUIRED:
AR NPN Isopropyl Alcohol
REPAIR PROCEDURE:
This bulletin involves removing the slip coating on the weatherstrip and mounting flange.
1. Remove the top half of the body mounted weatherstrip from the mounting flange starting at the
upper B-pillar corner down to the beltline at the A-pillar and B-pillar. Leave the bottom half of the
weatherstrip installed.
2. Apply alcohol to a clean rag or paper towel and wipe both sides of the sheet metal flange the
seal mounts to.
3. Use a clean portion of the rag with alcohol on it and wipe the weatherstrip throat/groove/slot that
mounts over the sheet metal flange. Try to get the rag as deep into the throat of the seal as
possible without bending it open. If done properly, there will be some black residue on the rag from
the weatherstrip.
4. If the throat of the weatherstrip becomes opened up, squeeze it back with hand pressure.
5. Reinstall the weatherstrip on the flange, make sure it is fully seated.
6. Repeat steps 1 through 5 for the other side.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 23-51-09-92 0.3 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation
Brake Switch (Cruise Control): Description and Operation
SYSTEM OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is
mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting
bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Page 8314
Brake Switch (Cruise Control): Testing and Inspection
Fig. 21 Stop Lamp Switch
1. Remove the stop lamp switch, refer to Stop Switch Removal/Installation. Disconnect connector
from stop lamp switch. Using an ohmmeter, switch
continuity may be checked as follows:
2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch
plunger depressed, there should be continuity:
- Between Pin 1 and Pin 2.
- Between Pin 3 and Pin 4.
4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. 5.
See Stop lamp switch adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Brake Switch (Cruise Control) > Component Information > Description and
Operation > Page 8315
Brake Switch (Cruise Control): Service and Repair
REMOVAL
Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a
counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from
bracket. Disconnect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch
with the plunger facing forward in car. There is an index key on the switch that mates with the
bracket slot at the top of the square hole. Align key and push switch into square hole in bracket
while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise
approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is
released. Pull back on the pedal to assure correct adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations
Speed Control Switches
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Clutch Switch, Cruise Control > Component Information > Locations > Page
8319
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8323
Vehicle Speed Control Servo - 4 Way
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8324
Cruise Control Servo: Description and Operation
SYSTEM OPERATION
The servo unit consists of a solenoid valve body, and a vacuum chamber. The PCM controls the
solenoid valve body. The solenoid valve body controls the application and release of vacuum to the
diaphragm of the vacuum servo. The servo unit cannot be repaired and is serviced only as a
complete assembly.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8325
Cruise Control Servo: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Remove air cleaner resonator.
Fig. 11 Speed Control Cable End
3. Disconnect the throttle and speed control cable ends from throttle body.
Speed Control Cable Case And Vacuum Line - Typical
4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Disconnect
vacuum line from nipple on air intake plenum. 6. Remove tie wrap holding vacuum line, throttle
cable, and speed control cable together.
Speed Control Servo
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo > Component Information > Locations > Page 8326
7. Remove bolt holding speed control servo to side of battery tray/vacuum reservoir. 8. Remove
speed control servo from battery tray. 9. Disconnect wire connector from speed control servo.
10. Disconnect vacuum line from speed control servo that leads to the battery tray/vacuum
reservoir. 11. Remove speed control servo.
INSTALLATION
- Transfer speed control cable to replacement speed control servo. Reverse the preceding
operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and
Operation
Cruise Control Servo Cable: Description and Operation
SYSTEM OPERATION
The speed control servo cable is connected between the speed control vacuum servo diaphragm
and the throttle body control linkage. This cable causes the throttle control linkage to open or close
the throttle valve in response to movement of the vacuum servo diaphragm.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Servo Cable > Component Information > Description and
Operation > Page 8330
Cruise Control Servo Cable: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Remove air cleaner resonator.
Fig. 11 Speed Control Cable End
3. Disconnect throttle and speed control cable ends from throttle body.
Speed Control Cable
4. Depress lock tabs holding speed control cable casing to cable mount bracket. 5. Remove tie
wrap holding vacuum line, throttle cable, and speed control cable together. 6. Remove nuts holding
speed control cable case to servo. 7. Remove cable case from servo. 8. Remove hairpin clip
holding cable end to servo diaphragm. 9. Remove speed control cable.
INSTALLATION
- Reverse the preceding operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8334
Cruise Control Switch: Description and Operation
SYSTEM OPERATION
There are two separate switch pods that operate the speed control system. The
steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner 5 manual
for more information on speed control switch functions and setting procedures.
When speed control is selected by depressing the ON switch, the PCM allows a set speed to be
stored in RAM for speed control. To store a set speed, depress the SET switch while the vehicle is
moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes
cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral.
The speed control can be disengaged manually by: Stepping on the brake pedal
- Depressing the OFF switch
- Depressing the CANCEL switch.
NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored
in the PCM.
For added safety,the speed control system is programmed to disengaged for any of the following
conditions: An indication of Park or Neutral
- An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged)
- Excessive engine rpm (indicates that the transmission may be in a low gear)
- The VSS signal increases at a rate of 10 mph per second (indicates that the coefficient of friction
between the road surface and tires is extremely low)
- The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have
decelerated at an extremely high rate)
- If the actual speed is not within 20 mph of the set speed
The previous disengagement conditions are programmed for added safety.
Once the speed control has been disengaged, depressing the ACCEL switch when speed is
greater than 25 mph restores the vehicle to the target speed that was stored in the PCM.
NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM.
While the speed control is engaged, the driver can increase the vehicle speed by depressing the
ACCEL switch. The new target speed is stored in the PCM when the ACCEL is released. The PCM
also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for
each momentary switch activation of the ACCEL switch. The PCM also provides a means to
decelerate without disengaging speed control. To decelerate from an existing recorded target
speed, depress and hold the COAST switch until the desired speed is reached, then release the
switch.
The individual switches cannot be repaired. If one switch fails, the entire switch module must be
replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Switch > Component Information > Diagrams > Page 8335
Cruise Control Switch: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove
airbag/horn pad from steering wheel. 4. Disconnect wire connector from horn switch, airbag, and
speed control switches.
Speed Control Switches
5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control
switch from airbag/horn pad.
INSTALLATION
- Reverse the preceding operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does
Not Maintain Speed on Grades
Cruise Control Vacuum Reservoir: Customer Interest Speed Control - Does Not Maintain Speed on
Grades
NUMBER: 08-27-99
GROUP: Electrical
EFFECTIVE DATE: Aug. 27, 1999
SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade
OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because
of speed control vacuum loss while on up hill grade.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED
WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE.
SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the
speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir
assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under
low manifold vacuum conditions. The valve may become contaminated and cause it not to seal
intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade.
DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative
and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the
vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the
speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum
reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes
perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of
vacuum leak is found, perform the Repair Procedure.
PARTS REQUIRED:
1 04716740AB Tray, Battery/Vacuum Reservoir
EQUIPMENT REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Customer Interest for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed Control - Does
Not Maintain Speed on Grades > Page 8344
Hand Vacuum Pump
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the nut and two bolts from the battery tray, Figure 1.
2. Remove the speed control servo attaching bolt from the battery tray.
3. Disconnect the vacuum lines from the battery tray vacuum reservoir.
4. Remove the battery tray from the vehicle and discard.
5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB.
6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.).
7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.).
8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.)
9. Connect the positive and negative battery terminals.
10. Set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-08-05-90 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed
Control - Does Not Maintain Speed on Grades
Cruise Control Vacuum Reservoir: All Technical Service Bulletins Speed Control - Does Not
Maintain Speed on Grades
NUMBER: 08-27-99
GROUP: Electrical
EFFECTIVE DATE: Aug. 27, 1999
SUBJECT: Speed Control Does Not Maintain Set Speed While Climbing a Grade
OVERVIEW: This bulletin involves replacing the battery tray/vacuum reservoir assembly because
of speed control vacuum loss while on up hill grade.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
NOTE:
THIS BULLETIN APPLIES TO VEHICLES BUILT PRIOR TO SEPT. 1, 1999 AND EQUIPPED
WITH SPEED CONTROL, SALES CODE NHM) AND A GASOLINE ENGINE.
SYMPTOM/CONDITION: Vehicle loses more than 5 mph (8 kph) while climbing a grade with the
speed control engaged because of a leaking check valve in the battery tray/vacuum reservoir
assembly. The check valve traps vacuum in the reservoir to allow the speed control to work under
low manifold vacuum conditions. The valve may become contaminated and cause it not to seal
intermittently. This can cause a loss of vacuum to the servo while driving on a long up hill grade.
DIAGNOSIS: Verify the ignition switch and all accessories are turned off. Disconnect the negative
and positive battery cables. Remove the battery hold down (Figure 1). Remove the battery from the
vehicle. Disconnect the vacuum line at the vacuum reservoir on the battery tray that goes to the
speed control servo. Connect a hand held vacuum pump to the small/top nipple on the vacuum
reservoir and apply 20 in. of vacuum. If the vacuum leaks down more than 2 in. in five minutes
perform the Repair Procedure, if not look for other sources of vacuum leaks. If no other source of
vacuum leak is found, perform the Repair Procedure.
PARTS REQUIRED:
1 04716740AB Tray, Battery/Vacuum Reservoir
EQUIPMENT REQUIRED:
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > All Technical Service Bulletins for Cruise Control Vacuum Reservoir: > 08-27-99 > Aug > 99 > Speed
Control - Does Not Maintain Speed on Grades > Page 8350
Hand Vacuum Pump
REPAIR PROCEDURE: THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE
SERVICE PROGRAM AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE
FACILITY SPECIAL EQUIPMENT.
1. Remove the nut and two bolts from the battery tray, Figure 1.
2. Remove the speed control servo attaching bolt from the battery tray.
3. Disconnect the vacuum lines from the battery tray vacuum reservoir.
4. Remove the battery tray from the vehicle and discard.
5. Connect the vacuum lines to the revised battery tray vacuum reservoir, p/n 04716740AB.
6. Attach the speed control servo to the battery tray. Tighten the bolt to 6 Nm. (50 in. lbs.).
7. Install the battery tray, tighten the nut and two bolts to 16 Nm. (140 in. lbs.).
8. Install the battery; tighten the hold down clamp bolt to 20 Nm (180 in. lbs.)
9. Connect the positive and negative battery terminals.
10. Set the clock to the correct time.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-08-05-90 0.3 Hrs.
FAILURE CODE: P8 - New Part
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Page 8351
Cruise Control Vacuum Reservoir: Description and Operation
SYSTEM OPERATION
The reservoir contains a one-way check valve to trap engine vacuum in the reservoir. When engine
vacuum drops, as in climbing a grade while driving, the reservoir supplies the vacuum needed to
maintain proper speed control operation. The vacuum reservoir cannot be repaired and must be
replaced if faulty.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Page 8352
Cruise Control Vacuum Reservoir: Testing and Inspection
1. Turn ignition switch to the ON position without starting engine. Activate speed control ON switch.
Fig. 4 Servo Harness Connector
2. Disconnect the four-way electrical connector and the vacuum harness at the servo. 3. Connect a
jumper wire from Pin 3 of the servo to Pin 3 of the wire connector. 4. Ground Pins 2 and 4 in the
servo. Do not connect pin 1. 5. Connect a hand held vacuum pump to the vacuum nipple and apply
10 - 15 inches of vacuum. 6. If servo pulls cable, replace servo. 7. Ground Pin 1 on servo. 8. Check
that the throttle cable pulls in and holds as long as the vacuum pump is connected. After one
minute, check if cable is still holding. If cable
does not hold replace the servo.
9. Disconnect jumper from pin 3. Cable should return to rest position. If not, replace servo.
10. Connect 4 way electrical connector and vacuum harness to servo.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Cruise Control Vacuum Reservoir > Component Information > Technical
Service Bulletins > Page 8353
Cruise Control Vacuum Reservoir: Service and Repair
REMOVAL
1. Disconnect negative cable from battery. 2. Remove battery. 3. Remove battery tray. 4.
Disconnect vacuum hoses from vacuum reservoir
INSTALLATION
1. Connect vacuum hoses to vacuum reservoir. 2. Install battery tray 3. Install battery. 4. Connect
negative cable to battery.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation
Brake Switch (Cruise Control): Description and Operation
SYSTEM OPERATION
Vehicles equipped with the speed control option use a dual function stop lamp switch. The switch is
mounted in the same location as the conventional stop lamp switch, on the brake pedal mounting
bracket under the instrument panel. The PCM monitors the state of the dual function stop lamp
switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Page 8358
Brake Switch (Cruise Control): Testing and Inspection
Fig. 21 Stop Lamp Switch
1. Remove the stop lamp switch, refer to Stop Switch Removal/Installation. Disconnect connector
from stop lamp switch. Using an ohmmeter, switch
continuity may be checked as follows:
2. With switch plunger released, there should be continuity between Pin 5 and Pin 6. 3. With switch
plunger depressed, there should be continuity:
- Between Pin 1 and Pin 2.
- Between Pin 3 and Pin 4.
4. If the above results are not obtained, the stop lamp switch is defective or out of adjustment. 5.
See Stop lamp switch adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Brake Switch (Cruise Control) >
Component Information > Description and Operation > Page 8359
Brake Switch (Cruise Control): Service and Repair
REMOVAL
Remove the switch from the bracket by depressing the brake pedal and rotating the switch in a
counterclockwise direction approximately 30 degrees. Pull the switch rearward and remove from
bracket. Disconnect wiring harness connector.
INSTALLATION
Before installing the switch, reset the adjustable switch plunger by pulling on the plunger head until
the plunger reaches the end of its travel. A ratcheting sound will be heard during this procedure.
Connect the wiring harness to the switch. Mount the switch into the bracket by holding the switch
with the plunger facing forward in car. There is an index key on the switch that mates with the
bracket slot at the top of the square hole. Align key and push switch into square hole in bracket
while depressing the brake pedal. Once the switch is seated in the hole, rotate clockwise
approximately 30 degrees to lock into place. The switch will automatically adjust when the pedal is
released. Pull back on the pedal to assure correct adjustment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Locations
Speed Control Switches
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Clutch Switch, Cruise Control >
Component Information > Locations > Page 8363
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Page 8367
Cruise Control Switch: Description and Operation
SYSTEM OPERATION
There are two separate switch pods that operate the speed control system. The
steering-wheel-mounted switches use multiplexed circuits to provide inputs to the PCM for ON,
OFF, RESUME, ACCELERATE, SET, DECEL and CANCEL modes. Refer to the owner 5 manual
for more information on speed control switch functions and setting procedures.
When speed control is selected by depressing the ON switch, the PCM allows a set speed to be
stored in RAM for speed control. To store a set speed, depress the SET switch while the vehicle is
moving at a speed between 30 and 85 mph. In order for the speed control to engage, the brakes
cannot be applied, nor can the gear selector be indicating the transmission is in Park or Neutral.
The speed control can be disengaged manually by: Stepping on the brake pedal
- Depressing the OFF switch
- Depressing the CANCEL switch.
NOTE: Depressing the OFF switch or turning off the ignition switch will erase the set speed stored
in the PCM.
For added safety,the speed control system is programmed to disengaged for any of the following
conditions: An indication of Park or Neutral
- An rpm increase without a VSS signal increase (indicates that the clutch has been disengaged)
- Excessive engine rpm (indicates that the transmission may be in a low gear)
- The VSS signal increases at a rate of 10 mph per second (indicates that the coefficient of friction
between the road surface and tires is extremely low)
- The VSS signal decreases at a rate of 10 mph per second (indicates that the vehicle may have
decelerated at an extremely high rate)
- If the actual speed is not within 20 mph of the set speed
The previous disengagement conditions are programmed for added safety.
Once the speed control has been disengaged, depressing the ACCEL switch when speed is
greater than 25 mph restores the vehicle to the target speed that was stored in the PCM.
NOTE: Depressing the OFF switch will erase the set speed stored in the PCM's RAM.
While the speed control is engaged, the driver can increase the vehicle speed by depressing the
ACCEL switch. The new target speed is stored in the PCM when the ACCEL is released. The PCM
also has a "tap-up" feature in which vehicle speed increases at a rate of approximately 2 mph for
each momentary switch activation of the ACCEL switch. The PCM also provides a means to
decelerate without disengaging speed control. To decelerate from an existing recorded target
speed, depress and hold the COAST switch until the desired speed is reached, then release the
switch.
The individual switches cannot be repaired. If one switch fails, the entire switch module must be
replaced.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Cruise Control Switch > Component
Information > Diagrams > Page 8368
Cruise Control Switch: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. Disconnect battery negative cable. 3. Remove
airbag/horn pad from steering wheel. 4. Disconnect wire connector from horn switch, airbag, and
speed control switches.
Speed Control Switches
5. Remove screws holding speed control switch to airbag/horn pad. 6. Separate speed control
switch from airbag/horn pad.
INSTALLATION
- Reverse the preceding operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > Customer Interest for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page
8377
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Sensors and Switches - Cruise Control > Vehicle Speed Sensor/Transducer Cruise Control > Component Information > Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed
Sensor/Transducer - Cruise Control: > 21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page
8383
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr
> 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: Customer Interest Speed Sensor - Intermittent
Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > Customer Interest for Vehicle Speed Sensor/Transducer - Cruise Control: > 21-06-99 > Apr
> 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8392
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control
Vehicle Speed Sensor/Transducer - Cruise Control: All Technical Service Bulletins Speed Sensor Intermittent Loss of Cruise Control
Number: 21-06-99
Group: Transmission
Date: April 2, 1999
SUBJECT: Intermittent Loss of Speed Control
OVERVIEW: This bulletin involves replacing the input and output speed sensor connectors.
MODELS:
1989 - 1995 (AA) Spirit/Acclaim/LeBaron Sedan
1989 - 1993 (AC) Dynasty/New Yorker/New Yorker Salon
1990 - 1993 (AG) Daytona
1990 - 1995 (AJ) LeBaron Coupe/LeBaron Convertible
1992 - 1994 (AP) Shadow/Shadow Convertible/Sundance
1990 - 1991 (AQ) Chrysler Maserati TC
1989 - 1995 (AS) Town & Country/Caravan/Voyager
1990 - 1993 (AY) Imperial/New Yorker Fifth Avenue
1993 - 1995 (ES) Chrysler Voyager (International Market)
1995 - 1999 (FJ) Sebring/Avenger/Talon
1996 - 1999 (GS) Chrysler Voyager (International Market)
1995 - 1999 (JA) Cirrus/Stratus/Breeze
1996 - 1999 (JX) Sebring Convertible
1993 - 1997 (LH) Concorde/Intrepid/Vision/New Yorker/LHS/300M
1996 - 1999 (NS) Town & Country/Caravan/Voyager
1997 (PR) Prowler
NOTE:
THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A 41TE/AE BUILT BEFORE
AUGUST 8, 1998 (MDH O8O8XX) OR 42LE TRANSAXLE THROUGH THE 1997 MODEL YEAR.
SYMPTOM/CONDITION: Intermittent loss of speed control condition persists after either the
transaxle input speed sensor or output speed sensor has been replaced. The sensor connectors
should be checked for spread terminals.
DISCUSSION: The input/output speed sensor supplier changed effective with the 1998 model year
for LH vehicles and August 8, 1998 for 41TE/AE equipped vehicles. The terminal layout is slightly
different between the old and new sensors. When a new sensor is installed on an early vehicle the
connector terminals may be spread from the original sensor and may cause an intermittent speed
control condition. Anytime a new sensor is installed on an early vehicle the connector must also be
replaced.
PARTS REQUIRED:
1 05014469AA Wiring Repair Package, Input Speed Sensor
1 05014471AA Wiring Repair Package, Output Speed Sensor
REPAIR PROCEDURE:
1. Disconnect and isolate negative battery cable.
2. Raise vehicle on a suitable hoist.
3. Locate and disconnect the input and/or output sensor connectors.
4. If required, detach the harness clip above the input/output sensors and detach the O2 sensor
fastener (Christmas tree type fastener).
5. Remove the end tape from the input/output harness and push back the convolute tubing.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Cruise Control > Vehicle Speed Sensor/Transducer - Cruise Control > Component Information
> Technical Service Bulletins > All Technical Service Bulletins for Vehicle Speed Sensor/Transducer - Cruise Control: >
21-06-99 > Apr > 99 > Speed Sensor - Intermittent Loss of Cruise Control > Page 8398
6. Cut the harness just above the top of the connector to remove the input and/or output connector.
7. Remove approximately 1/2 inch of insulation from the end of the two wires.
8. From the wiring repair package, locate the wiring repair harness. Approximately 1/4 inch of
insulation has been removed from the repair harness wires.
9. Place a heat shrink tube over each of the two wires on the repair harness.
10. Using Miller Crimp Tool # 8272 or equivalent, crimp the splice band to the transmission harness
and repair harness wires. Repeat procedure for the second wire.
11. Solder the connection together using rosin core type solder.
12. Center the heat shrink tube over the splice joint. Heat using a heat gun until the tubing is tightly
sealed and sealant comes out of both ends of the tubing.
13. Cover wires with attached convolute and add additional convolute from the repair package.
14. Tape ends with black electrical tape.
15. Route engine harness behind the coolant lines and dipstick tube, away from the exhaust.
16. If required connect O2 sensor fastener and attach upper harness clip.
17. Connect input/output sensor connectors.
18. Connect negative battery cable.
19. Verify transmission systems are functioning as designed.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No: 08-90-99-93 Wiring Harness Repair 0.5 Hrs.
FAILURE CODE: XX - Service Adjustment
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > ABS Light > Component Information >
Description and Operation
ABS Light: Description and Operation
The ABS system uses a yellow colored ABS Warning Lamp. The ABS warning lamp is located on
the right side of the message center located at the top of the instrument panel. The purpose of the
warning lamp is discussed in detail below.
The ABS warning lamp will turn on when the Controller Antilock Brake (CAB) detects a condition
which results in a shutdown of ABS function or when the body controller does not receive C2D
messages from the CAB. When the ignition key is turned to the on position, the ABS Warning
Lamp is on until the CAB completes its self tests and turns the lamp off (approximately 4 seconds
after the ignition switch is turned on). Under most conditions, when the ABS warning lamp is on,
only the ABS function of the brake system is affected. The standard brake system and the ability to
stop the car will not be affected when only the ABS warning lamp is on.
The ABS warning lamp is controlled by the CAB and the body controller through a diode located in
the wiring harness junction block. The junction block is located under the instrument panel to the
left of the steering column. The CAB and the body controller, controls the yellow ABS warning lamp
by directly grounding the circuit.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Air Conditioning Indicator Lamp >
Component Information > Service and Repair
Air Conditioning Indicator Lamp: Service and Repair
REMOVAL
1. Remove rear heater-A/C control from trim panel. 2. On the back of control opposite from the wire
connectors, locate the bulb socket lug. 3. Rotate the socket counterclockwise and pull the socket
from the control.
INSTALLATION
- For installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions
Audible Warning Device: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8410
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8411
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8412
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8413
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8414
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8415
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8416
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8417
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8418
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8419
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8420
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8421
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8422
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8423
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8424
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8425
Audible Warning Device: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8426
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8427
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Audible Warning Device > Component
Information > Diagrams > Diagram Information and Instructions > Page 8428
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark 20 ABS System Test
Revisions
NUMBER: 26-12-97I
GROUP: Miscellaneous
DATE: December, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1998 Teves Mark 20 ABS Diagnostic Manual - Publication Number - 81-699-97013
DESCRIPTION OF CHANGES
Revisions to the ABS warning lamp test
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8433
94
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8434
95
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8435
Brake Warning Indicator: Technical Service Bulletins Brakes - Teves Mark IV/Teves Mark 20 ABS
Revisions
NUMBER: 26-12-97F
GROUP: Miscellaneous
DATE: December, 1997
REVISIONS ARE HIGHLIGHTED WITH BLACK BARS IN THE MARGIN
Models: 1997-1998 Teves Mark IV, Teves Mark 20 ABS Diagnostic Manual - Publication Number 81-699-97012
DESCRIPTION OF CHANGES
Revisions to the ABS warning light procedure
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8436
244
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Brakes - Teves Mark 20 ABS System Test Revisions > Page 8437
245
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Brake Warning Indicator > Component
Information > Technical Service Bulletins > Page 8438
Brake Warning Indicator: Description and Operation
The red Brake warning lamp is located in the instrument panel cluster and is used to indicate a low
brake fluid condition or that the parking brake is applied. In addition, the brake warning lamp is
turned on as a bulb check by the ignition switch every time the ignition switch is turned to the crank
position.
The warning lamp bulb is supplied a 12 volt ignition feed anytime the ignition switch is on. The bulb
is then illuminated by completing the ground circuit either through the park brake switch, the fluid
level sensor in the master cylinder reservoir, or the ignition switch when it is turned to the crank
position.
The Brake Fluid Level sensor is located in the brake fluid reservoir of the master cylinder assembly.
The purpose of the sensor is to provide the driver with an early warning that brake fluid level in the
master cylinder fluid reservoir has dropped to below normal. This may indicate: (1) Abnormal loss
of brake fluid in the master cylinder fluid reservoir resulting from a leak in the hydraulic system. (2)
Brake shoe linings which have worn to a point requiring replacement.
As the brake fluid drops below the minimum level, the brake fluid level sensor closes to ground the
brake warning light circuit. This will turn on the red brake warning light. At this time, master cylinder
fluid reservoir should be checked and filled to the full mark with DOT 3 brake fluid. If brake fluid
level has dropped below the add line in the master cylinder fluid reservoir, the entire brake
hydraulic system should be checked for evidence of a leak.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Cigarette Lighter > Cigarette Lighter
Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions
Compass: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8448
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8449
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8450
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8451
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8452
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8453
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8454
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8455
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8456
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8457
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8458
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8459
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8460
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8461
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8462
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8463
Compass: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8464
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8465
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8466
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Diagram Information and Instructions > Page 8467
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Diagrams > Page 8468
Compass: Description and Operation
SYSTEM OPERATION
Compass Mini Trip Computer (CMTC) The Compass mini-trip computer (CMTC) system is located
in the overhead console. CMTC consists of an electronic control module with a vacuum fluorescent
display (VFD) and function switches. The CMTC consists of an electronic module that displays
compass, trip computer and temperature features. Actuating the STEP switch will cause the CMTC
to change mode of operation when the ignition is ON.
Examples: Compass/Temperature
- Trip odometer (ODO)
- Average miles per gallon (ECO)
- Instant miles per gallon (ECO)
- Distance to empty (DTE)
- Elapsed time (ET)
- Off
The CMTC module in the overhead console has three buttons used to select various functions. The
CMTC selector buttons will not operate until the ignition is in the RUN position.
When the ignition switch is first turned to the Run position the CMTC display: Blanks momentarily
- All segments of the VFD will light for one second
- Blanks momentarily
- Returns to the last mode setting selected before the ignition was last switched OFF.
Compass The CMTC is self calibrating and usually requires no adjustment. The compass will
continuously perform a slow calibration to compensate for small magnetic variations common to
any automobile. Uncommon magnetic shifts may be caused by items such as magnetic base
antennas, which can permanently alter the magnetic field of the vehicle roof panel. If excessive
magnetic field continues for 5 minutes, the compass heading will go blank and only the CAL
symbol will illuminate. When this occurs, the vehicle roof panel may require demagnetizing. Refer
to the demagnetizing procedure.
Moderate magnetic shifts may, on very rare occasions, cause the compass heading to display only
one or two of the eight possible headings. Although the compass will eventually compensate for
this shift, it could take several ignition cycles. The compensation process can be expedited by
manually activating the fast calibration routine. Refer to the fast calibrating procedure. This
procedure may be performed anytime that the compass appears to be inaccurate.
If the calibration data stored in the body control module is not received, the compass will read only
NE North-East. The CMTC is self calibrating and requires no adjusting. The word CAL is displayed
to show that the compass is in calibration mode. CAL will turn off after the vehicle has gone
through three complete circles without stopping, in an area free of magnetic disturbance. If module
displays temperature while the compass is blank, turn off ignition and run self diagnostics then
demagnetize the vehicle. After demagnetizing, check compass calibration number, refer to Self
Diagnostic Test. If greater than 15, demagnetize again until reading is less than 15. If compass still
goes blank after demagnetizing then check internal diagnostics and demagnetize.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Component Tests and General Diagnostics
Compass: Component Tests and General Diagnostics
Self-Check For Compass Mini-Trip (CMTC)
The Compass Mini Trip Computer (CMTC) is capable of performing a diagnostic self check on
many of its internal functions. CMTC diagnostics may be performed using a scan tool and the
proper Body Control Module Testing and Inspection Procedures or by using the following
procedure.
1. With the ignition switch in the OFF position, press both the US/M and STEP buttons. 2. Turn
ignition switch to the ON position. The CMTC will perform internal checks while lighting all
segments of the vacuum florescent display.
Upon completion of the internal check the CMTC will display. PASS
- FAIL
- CCD
If any segment of the CMTC fails to light replace the module.
If FAIL is displayed replace the module.
If CCD is displayed check the CCD (Information Bus) and Body Control Module (BCM) for proper
operation. If the CCD bus and the BCM are OK, replace the CMTC module.
Additional diagnostic trouble code information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Diagnostic Charts
Diagnostic information can be found at Body Control Module, Testing and Inspection, Diagnostic
Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Page 8471
Compass: Adjustments
Setting the Compass
The compass/mini-trip module is self-calibrated and requires no adjustment. The word CAL will be
displayed to indicate that the compass is in the fast calibrating mode. CAL will turn off after the
vehicle has gone in three complete circles without stopping, in an area free of magnetic
disturbance.
If the module displays the temperature while the compass is blank or shows a false reading, the
vehicle must be demagnetized.
If the compass still goes blank after the vehicle is demagnetized, the compass/mini-trip module
must be replaced.
Setting the Variance
Variance is the difference between magnetic north and geographic north. To determine the
variance for the area you are in, refer to the zone map above. The number shown for your area is
the variance number for your area.
1. Set the compass/mini-trip console (CMTC) to compass/temperature mode. 2. Press and hold
down the RESET button for 5 seconds. NOTE: If the button is held for 10 seconds instead of 5, the
CMTC will set the variance
to 8 and enter the fast calibration mode.
3. The VAR light will come on and the last variance setting will be displayed. 4. Press the STEP
button to set the zone number. 5. Press the US/M button and resume normal operation.
NOTE: Do not attach any magnetic device such as a magnetic CB antenna to the vehicle. This can
cause the compass to give false readings.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Page 8472
Compass: Service and Repair
Variance Settings
COMPASS CALIBRATION PROCEDURE
Variance is the difference between magnetic North and geographic North. To adjust the compass
variance set the CMTC to Compass/Temperature mode and press RESET buttons for 5 seconds.
The symbol VAR and the current variance zone number will be displayed. Press the STEP button
to select the proper variance zone. Press the US/Metric button to save the new variance zone and
normal CMTC operation. If both buttons are held for 10 seconds instead 5 seconds the CMTC will
set variance to 8 and enter the fast calibration mode.
COMPASS CALIBRATION PROCEDURE (FAST METHOD)
When the compass is subjected to excessive magnetic fields, the CMTC automatically enters a fast
calibration mode where is tries to compensate for the large magnetic shifts.
If the compass is inaccurate, appears to be inaccurate and the CAL is not illuminated the fast
calibration mode may be manually entered by using the following procedure.
1. Set the CMTC to Compass/Temperature mode and press the reset button for 10 continuous
seconds. Manual activation of the fast calibration is
generally not required.
2. Compass variance sets to the default of 8 after the fast calibration is manually activated. 3.
Complete the compass variance setting procedure by referring to the Compass Variance
Procedure. 4. Drive the vehicle in three 3600 turns in an area free from large metal objects. If the
CAL symbol remains lit after completing this step, the roof
panel may need demagnetizing.
DEMAGNETIZING PROCEDURE
A magnetic field can adversely affect the compass. Magnetic interference can magnetize the roof
panel. Magnetizing can be caused by placing a permanent magnet in contact with the roof panel.
Example: Magnetic Base Antenna
- Magnetic screwdriver
- Audio speakers
- Refrigerator magnets
- Pizza Signs
- Bubble gum flasher lights
Removing magnetic interfering objects will usually restore normal compass operation. If the
compass display remains blank while the CAL label is illuminated, then the roof panel requires
demagnetizing. To demagnetize use Special Tool 6029 for demagnetizing the roof panel. The
demagnetizing procedure will demagnetize the roof and mounting screws in the overhead console.
It is important that you follow the instructions below exactly. The mounting screws and the
mounting brackets around the compass area are steel, and therefore aid in the demagnetizing of
the roof panel.
1. Be sure the ignition switch is in the OFF position before you begin the demagnetize procedure.
2. Plug the demagnetizing tool into a standard 110/115 volt AC outlet, keeping the demagnetizing
tool at least 12 inches away from the compass area
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Compass > Component Information >
Testing and Inspection > Page 8473
when plugging it in.
3. Slowly approach and contact the console mounting screw with the plastic coated tip of the tool
for at least two seconds. 4. With the demagnetizing tool still energized, slowly back it away from the
screw until the tip is at least 12 inches from the screw head. 5. Repeat the last step with all the
console mounting screws. 6. After you have pulled at least 12 inches from the last screw, remove
the demagnetizing tool from inside vehicle and disconnect it from the
electrical outlet.
7. Place an 8 1/2 X 11 inch piece of paper length-wise on the roof of vehicle directly above
compass. The purpose of the paper is to protect the roof
panel from scratches and define the area to be demagnetized.
8. Plug in the demagnetizing tool, keeping it at least two feet away from the compass unit. 9. Slowly
approach the center of the roof panel at the windshield with the demagnetizing tool plugged in.
10. Contact the roof panel with the tip of the tool. Using slow sweeping motions of 1/2 inch between
sweeps. Move the tool approximately four
inches either side of the center line and at least 11 inches back from the windshield.
11. With the demagnetizing tool still energized, slowly back away from the roof panel until the tip is
at least two feet from the roof before unplugging
the tool.
12. Recalibrate compass, refer to the compass calibration procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Dashboard / Instrument Panel > Air
Bag(s) Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8480
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions
Driver/Vehicle Information Display: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8485
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8486
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8487
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8488
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8489
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8490
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8491
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8492
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8493
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8494
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8495
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8496
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8497
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8498
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8499
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8500
Driver/Vehicle Information Display: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8501
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8502
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8503
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8504
Driver/Vehicle Information Display: Electrical Diagrams
Information Center
Wiring Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8505
Message Center (Part 1 Of 4)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8506
Message Center (Part 2 Of 4)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8507
Message Center (Part 3 Of 4)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Diagrams > Diagram Information and Instructions > Page 8508
Message Center (Part 4 Of 4)
NOTE: To view sheets referred in these diagrams, see Diagram Information and
Instructions/Complete Body and Chassis Diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Message Center
Driver/Vehicle Information Display: Service and Repair Message Center
REMOVAL
1. Remove A-pillar trim. 2. Remove instrument panel top cover. Refer to instrument panel top cover
removal procedures. 3. Disconnect the wire connector from back of message center. 4. Remove
screws holding message center to instrument panel top cover. 5. Remove message center from
instrument panel top cover.
INSTALLATION
1. Place message center in position on top cover. 2. Install screws to hold message center to
instrument panel top cover. 3. Connect wire connector into back of message center. 4. Install
instrument panel top cover. 5. Install A-pillar trim.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Driver/Vehicle Information Display >
Component Information > Service and Repair > Message Center > Page 8511
Driver/Vehicle Information Display: Service and Repair Message Center Lamp
REMOVAL
1. Remove instrument panel top cover. Refer to Instrument Panel Top Cover Removal procedures.
Message Center Lamp Location
2. Locate the lamp in question. 3. Remove lamp and check lamp. If lamp is good test the power
supply to the lamp.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > About Diagnostic Procedures
Fuel Gauge: Testing and Inspection About Diagnostic Procedures
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing
and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8516
Fuel Gauge: Testing and Inspection Diagnostic Chart
Fuel Gauge Diagnosis (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8517
Fuel Gauge Diagnosis (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8518
Fuel Gauge Diagnosis (Part 3 Of 3)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Fuel Gauge Sender > Component
Information > Locations > Page 8522
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service Precautions
Air Bag(s) Arming and Disarming: Service Precautions
WARNINGS:
- Before beginning any service procedures that involves removing the air bag. Remove and isolate
the negative (-) battery cable (ground) from the vehicle battery. This is the only sure way to disable
the air bag system. Failure to do this could result in accidental air bag deployment and possible
personal injury.
- The air bag system is a sensitive, complex electro-mechanical unit. Before attempting to
diagnose, remove or install the air bag system components you must first disconnect and isolate
the battery negative (ground) cable. Failure to do so could result in accidental deployment of the air
bag and possible personal injury the fasteners, screws, and bolts, originally used for the air bag
components, have special coatings and are specifically designed for the air bag system. they must
never be replaced with any substitutes. Anytime a new fastener is needed, replace with the correct
fasteners provided in the service package or fasteners listed in the parts books. Before servicing a
steering column equipped with an air bag, use proper and safe service procedures
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Disarming
Air Bag Disarming
WARNING: Disconnect and isolate the battery negative cable before beginning Air-bag System
component service procedures. This will disable the airbag system. Failure to disconnect the
battery could result in accidental airbag deployment and possible personal injury. Allow system capacitor to discharge for two minutes before removing airbag components
.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Air Bag(s)
Arming and Disarming > System Information > Service and Repair > Air Bag Disarming > Page 8529
Air Bag(s) Arming and Disarming: Service and Repair Air Bag Arming
Air Bag Arming
1. Connect scan tool (DRB) to Data Link connector, located at left side of the steering column and
at the lower edge of the lower instrument panel. 2. Turn the ignition key to ON position. Exit vehicle
with scan tool. Use the latest version of the proper cartridge. 3. After checking that no one is inside
the vehicle, connect the battery negative terminal. 4. Using the scan tool, read and record active
diagnostic code data. 5. Read and record any stored diagnostic codes. 6. Refer to the proper Body
Diagnostic Procedures if any diagnostic codes are found in Step 4 or Step 5. 7. Erase stored
diagnostic codes if there are no active diagnostic codes. If problems remain, diagnostic codes will
not erase. Refer to Air Bags to
diagnose the problem. If airbag warning lamp either fails to light, or goes on and stays on, there is
a system malfunction.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Instrument Cluster / Carrier > Instrument
Panel Circuit Board > Component Information > Service and Repair
Instrument Panel Circuit Board: Service and Repair
Instrument Cluster Printed Circuit Board
REMOVAL
1. Remove the instrument cluster. 2. Remove the instrument cluster back panel. 3. Disconnect the
electronic cluster wire connector from the printed circuit board. 4. Remove the screws holding wire
connector insulator to the instrument cluster shell and the printed circuit board. 5. Remove the
screws holding printed circuit board to the cluster shell. 6. Remove the printed circuit board from
the cluster.
INSTALLATION
- For Installation, reverse the above procedures. After installing the print circuit board it will have to
be calibrated using a scan tool (DRB III).
NOTE: Speedometer and/or Tachometer will not operate properly until all gauges have been
calibrated.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Maintenance Required Lamp/Indicator >
Component Information > Description and Operation
Maintenance Required Lamp/Indicator: Description and Operation
This vehicle does not have a Maintenance Reminder Light option.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > About Diagnostic Procedures
Odometer: Testing and Inspection About Diagnostic Procedures
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing
and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8540
Odometer: Testing and Inspection Odometer Diagnosis
Odometer Diagnosis (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8541
Odometer Diagnosis (Part 2 Of 2)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Odometer > Component Information >
Testing and Inspection > Page 8542
Odometer: Service and Repair
REMOVAL
1. Remove instrument cluster. 2. Remove cluster lens. 3. Disconnect wire connector from odometer
and transmission range indicator. 4. Remove screws holding odometer and transmission range
indicator to cluster shell. 5. Remove odometer and transmission range indicator from cluster.
INSTALLATION
1. Install odometer and transmission range indicator and attach to cluster shell. 2. Connect wire
connector into odometer and transmission range indicator. 3. Install cluster lens. 4. Install
instrument cluster.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Oil Pressure Sender > Component
Information > Locations
Engine Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside
Temperature Display Sensor > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Outside Temperature Display > Outside
Temperature Display Sensor > Component Information > Locations > Page 8550
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Relays and Modules - Instrument Panel >
Cigarette Lighter Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Fuel Gauge Sender > Component Information > Locations > Page 8559
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Outside Temperature Display Sensor > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Sensors and Switches - Instrument Panel
> Outside Temperature Display Sensor > Component Information > Locations > Page 8563
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures
Speedometer Head: Testing and Inspection About Diagnostic Procedures
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing
and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 8568
Speedometer Head: Testing and Inspection Speedometer Diagnosis
Speedometer Diagnosis (Part 1 Of 5)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 8569
Speedometer Diagnosis (Part 2 Of 5)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 8570
Speedometer Diagnosis (Part 3 Of 5)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 8571
Speedometer Diagnosis (Part 4 Of 5)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Speedometer Head > Component
Information > Testing and Inspection > About Diagnostic Procedures > Page 8572
Speedometer Diagnosis (Part 5 Of 5)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > About Diagnostic Procedures
Tachometer: Testing and Inspection About Diagnostic Procedures
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing
and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8577
Tachometer: Testing and Inspection Tachometer Test
Tachometer Diagnosis (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Tachometer > Component Information >
Testing and Inspection > About Diagnostic Procedures > Page 8578
Tachometer Diagnosis (Part 2 Of 2)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Description and Operation
Temperature Gauge: Description and Operation
At idle with Air Conditioning off the temperature gauge will rise slowly to about 5/8 gauge travel, the
fan will come on and the gauge will quickly drop to about 1/2 gauge travel. This is normal.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview
Temperature Gauge: Initial Inspection and Diagnostic Overview
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing
and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8584
Temperature Gauge: Component Tests and General Diagnostics
Temperature Diagnosis (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8585
Temperature Diagnosis (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Gauge > Component
Information > Testing and Inspection > Initial Inspection and Diagnostic Overview > Page 8586
Temperature Diagnosis (Part 3 Of 3)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Temperature Sensor (Gauge) >
Component Information > Specifications
Temperature Sensor (Gauge): Specifications
Temperature Gauge Sending Unit
........................................................................................................................................................... 7
Nm (60 inch lbs.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Traction Control Indicator Lamp >
Component Information > Testing and Inspection
Traction Control Indicator Lamp: Testing and Inspection
The traction control light is tested by cycling the traction control switch on and off. The traction
control switch used on this vehicle is a momentary contact type switch. The test procedure for the
traction control light is performed as follows: Press the traction control switch once and the "Trac
Off" lamp will illuminate. With the "Trac Off" lamp illuminated, press the traction control switch again
and the "Trac Off" lamp will turn off.
If the traction control lamp does not function as described in the test above, diagnosis of the
traction control switch, lamp, wiring and other related components of the traction control system is
required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures
Transmission Shift Position Indicator Lamp: Testing and Inspection About Diagnostic Procedures
These vehicle instrument clusters are equipped with a self diagnostic test feature to help identify
electronic problems. Prior to any test, perform the Self Diagnostic Test, found under Cluster
Diagnostics/Calibration at the Instrument Panel System level Testing and Inspection. See: Testing
and Inspection
The self diagnostic system monitors the CCD bus messages. If an electronic problem occurs, a
Diagnostic Trouble Code (DTC) will be displayed in the odometer window of the cluster. The
following CCD bus messages are continuously monitored by the diagnostic system:
- Body Control Module
- Powertrain Control Module
- Transmission Control Module, if equipped
NOTE: Additional diagnostic information can be found at Body Control Module, Testing and
Inspection, Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control
Module/Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8597
Transmission Shift Position Indicator Lamp: Testing and Inspection Electronic Gear Indicator
Display Diagnostic Chart
Electronic Gear Indicator Display Diagnosis (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8598
Electronic Gear Indicator Display Diagnosis (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8599
Electronic Gear Indicator Display Diagnosis (Part 3 Of 3)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Testing and Inspection > About Diagnostic Procedures > Page 8600
Transmission Shift Position Indicator Lamp: Testing and Inspection Mechanical Transmission
Range Indicator (PRND21) Diagnosis
Mechanical Transmission Range Indicator (PRND21) (Part 1 Of 2)
Mechanical Transmission Range Indicator (PRND21) (Part 2 Of 2)
Additional diagnostic information can be found at Body Control Module, Testing and Inspection,
Diagnostic Charts. See: Body and Frame/Body Control Systems/Body Control Module/Testing and
Inspection
Please also note that Instrument Panel Calibration can be found at Cluster Diagnostics/Calibration
Under Testing and Inspection at the system level. See: Testing and Inspection
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Service and Repair > Electronic Odometer and Transmission Range Indicator
Transmission Shift Position Indicator Lamp: Service and Repair Electronic Odometer and
Transmission Range Indicator
REMOVAL
1. Remove instrument cluster. 2. Remove cluster lens. 3. Disconnect wire connector from odometer
and transmission range indicator. 4. Remove screws holding odometer and transmission range
indicator to cluster shell. 5. Remove odometer and transmission range indicator from cluster.
INSTALLATION
1. Install odometer and transmission range indicator and attach to cluster shell. 2. Connect wire
connector into odometer and transmission range indicator. 3. Install cluster lens. 4. Install
instrument cluster.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Instrument Panel, Gauges and Warning Indicators > Transmission Shift Position Indicator
Lamp > Component Information > Service and Repair > Electronic Odometer and Transmission Range Indicator > Page
8603
Transmission Shift Position Indicator Lamp: Service and Repair Mechanical Transmission Range
Indicator
REMOVAL
1. Remove instrument cluster. 2. Remove cluster lens. 3. Remove screws holding mechanical
transmission range indicator to back of cluster lens. 4. Remove mechanical transmission range
indicator from cluster lens.
INSTALLATION
1. Position transmission range indicator on cluster lens. 2. Install mechanical range indicator and
attaching screws to back of cluster lens. 3. Install cluster lens. 4. Install instrument cluster.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Backup Lamp > Backup Light Bulb > Component Information > Service
and Repair
Backup Light Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-Up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Lamp > Brake Light Bulb > Component Information > Service and
Repair
Brake Light Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-Up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8616
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8617
Brake Light Switch: Service Precautions
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8618
Brake Light Switch: Description and Operation
The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped
with speed control, the stop lamp switch will deactivate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and
Center High Mount Stop Lamp (CHMSL) lamp, by supplying battery current to these lamps.
The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the
stop lamps.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8619
Brake Light Switch: Adjustments
1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise
direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch
firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until
it has ratcheted out to
its fully extended position.
4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting bracket. When switch is fully installed in the
square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the
bracket.
Stop Light Switch Location In Vehicle
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake
pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the
correct position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Brake Light Switch > Component Information > Locations > Page 8620
Brake Light Switch: Service and Repair
REMOVAL
Stop Lamp Switch
1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise
direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3.
Disconnect wiring harness connector from stop lamp switch.
INSTALLATION
NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of
the stop lamp switch until it has ratcheted out to
its fully extended position.
2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch
into the bracket using the following procedure. Depress the brake pedal as far down as possible.
Then install switch in
bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When
switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into
bracket.
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If to much force is used, damage to the stop lamp switch or striker can result.
4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger
to ratchet backward to the correct position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Center Mounted Brake Lamp > Center Mounted Brake Lamp Bulb >
Component Information > Service and Repair
Center Mounted Brake Lamp Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Disengage clips holding CHMSL access cover to
liftgate. 3. Separate cover from liftgate. 4. Rotate bulb socket counterclockwise one quarter turn.
CHMSL Bulb
5. Pull socket from lamp. 6. Pull bulb from socket.
INSTALLATION
1. Insert bulb into socket. 2. Insert socket into lamp. 3. Rotate bulb socket clockwise one quarter
turn. 4. Place CHMSL access cover in position on liftgate. 5. Engage clips to hold access cover to
liftgate. 6. Verify CHMSL operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb
Courtesy Lamp Bulb: Service and Repair Front Door Courtesy Lamp Bulb
REMOVAL
Door Courtesy Lamp Lens
1. Using a small, flat bladed pry tool, pry rear edge of courtesy lamp lens from courtesy lamp. 2.
Separate lens from lamp. 3. Squeeze brass lamp bulb contacts together gently
Door Courtesy Lamp Bulb
4. Disengage bulb wire contacts from lamp bulb contacts. 5. Separate bulb from lamp.
INSTALLATION
1. Position bulb to lamp. 2. Engage bulb wire contacts to lamp bulb contacts. 3. Insert long edge of
lens into lamp housing. 4. Press on center of lens to engage remainder of clips
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 8630
Courtesy Lamp Bulb: Service and Repair Header Reading / Courtesy Lamp Bulb
Reading/Courtesy Lamp Lens
REMOVAL
1. Insert a small, flat bladed pry tool at forward position between reading/courtesy lamp lens and
lamp housing. 2. Pry lamp lens from lamp housing. 3. Insert a small, flat bladed pry tool between
lamp light shield and lamp housing at inboard rear corner of light shield.
Reading/Courtesy Lamp Light Shield
4. Pry light shield from housing. 5. Carefully press forward lamp bulb contact toward opposite
contact and rotate. 6. Separate bulb from lamp bulb contacts.
INSTALLATION
1. Carefully press forward lamp bulb contact toward opposite contact and rotate bulb into position.
2. Position bulb to lamp bulb contacts. 3. Release lamp bulb contacts. 4. Insert outer edge of light
shield into lamp housing. 5. Rotate light shield upward and snap inboard edge into lamp housing. 6.
Position lens switch tab to lamp switch. 7. Press lens pivots to tabs on lamp housing until both
pivots are seated.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 8631
Courtesy Lamp Bulb: Service and Repair Liftgate Courtesy Lamp Bulb
REMOVAL
1. Remove liftgate courtesy lamp. 2. Insert a small, flat bladed pry tool between courtesy lamp lens
and courtesy lamp body.
Liftgate Courtesy Lamp Bulb
3. Carefully depress tabs holding lens to courtesy lamp body. 4. Separate lamp lens from lamp
body 5. Carefully press lamp bulb contact toward opposite contact. 6. Separate bulb from lamp
body.
INSTALLATION
1. Carefully press lamp bulb contact toward opposite contact. 2. Position bulb to lamp bulb
contacts. 3. Position long side of lamp lens to tabs on lamp body. 4. Press on center of lens to
engage tabs on opposite side of lamp body. 5. Install liftgate courtesy lamp.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 8632
Courtesy Lamp Bulb: Service and Repair Overhead Console Reading/Courtesy Lamp Bulb
REMOVAL
1. Using a trim stick, lightly pry outward the forward end of reading lamp lens. 2. Rotate reading
lamp bulb socket one quarter turn counter clockwise.
Reading/Courtesy Lamp
3. Pull socket out of lamp. 4. Pull bulb from socket.
INSTALLATION
1. Push bulb into socket. 2. Push socket into lamp. 3. Rotate reading lamp bulb socket one quarter
turn clockwise. 4. Insert tab on lamp lens between lamp switch and overhead console. 5. Snap lens
onto lamp lens pivots.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Courtesy Lamp Bulb > Component Information >
Service and Repair > Front Door Courtesy Lamp Bulb > Page 8633
Courtesy Lamp Bulb: Service and Repair Rail Lamp Module Bulb
REMOVAL
Rail Lamp Module Lens
1. Using a small screw driver, pry stationary end of rail lamp lens from rail lamp module. 2.
Separate lens tab from between rail lamp module and rail lamp switch. 3. Separate lens from lamp.
Rail Lamp Module Bulb
4. Pull bulb from lamp .
INSTALLATION
1. Push bulb into bulb contacts in rail lamp module. 2. Insert tab on lamp lens between rail lamp
module and rail lamp switch. 3. Snap lens onto lens pivots on module.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp > Component Information > Service
and Repair
Glove Box Lamp: Service and Repair
REMOVAL
1. Remove glove box lamp/switch from instrument panel.
Glove Box Lamp
2. Pull bulb from glove box lamp.
INSTALLATION
1. Push bulb into glove box lamp. 2. Install glove box lamp/switch in instrument panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Glove Box Lamp Switch > Component Information >
Service and Repair
Glove Box Lamp Switch: Service and Repair
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Glove Box Lamp And Switch
3. Disengage wire connector from glove box lamp and switch. 4. Remove glove box lamp and
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information >
Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information >
Locations > Page 8643
Interior Light Switch: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Courtesy Lamp > Interior Light Switch > Component Information >
Locations > Page 8644
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Locations
Daytime Running Lamp: Locations
Combination Flasher Location
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions (for Canadian vehicles), and has been designed with internal relays to take
advantage of low current switching requirements in the vehicle. It is plugged into the junction block
at positions three and four, where all wiring associated with its operation is terminated. The junction
block is adjacent to and left of the steering column of the vehicle.
On vehicles built for use in the United States, only position four is used. Vehicles built for use in
Canada utilize both positions three and four.
To gain access to the device, remove the lower steering column cover and knee blocker.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Daytime Running Lamp > Component Information > Locations > Page
8648
Daytime Running Lamp: Description and Operation
SYSTEM OPERATION
Junction Block Terminal Pins
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions (for Canadian vehicles), and has been designed with internal relays to take
advantage of low current switching requirements in the vehicle. It is plugged into the junction block
at positions three and four, where all wiring associated with its operation is terminated. The junction
block is adjacent to and left of the steering column of the vehicle.
On vehicles built for use in the United States, only position four is used. Vehicles built for use in
Canada utilize both positions three and four.
To gain access to the device, remove the lower steering column cover and knee blocker.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Dome Lamp > Dome Lamp Bulb > Component Information > Service and
Repair
Dome Lamp Bulb: Service and Repair
REMOVAL
1. Insert a small, flat bladed pry tool between dome lamp lens and dome lamp body on left side of
dome lamp.
Dome Lamp Bulb
2. Disengage left side of dome lamp lens from lamp body. 3. Pull bulb from lamp socket
INSTALLATION
1. Push bulb into lamp socket. 2. Pivot dome lamp lens upward. Verify that lamp lens hook is above
the headlining. 3. Engage left side of dome lamp lens to lamp body
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Bulb > Component Information >
Service and Repair
Fog/Driving Lamp Bulb: Service and Repair
REMOVAL
1. Remove fog lamp from vehicle. 2. Remove rear cover from fog lamp.
Fog Lamp Bulb
3. Disengage wire clip holding bulb in fog lamp. 4. Hinge wire retainer clip out of bulb removal path.
5. Pull bulb from lamp. 6. Disengage wire connector from fog lamp wire harness.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs with fingers or other oily surfaces, reduced bulb
life will result.
1. Engage wire connector into fog lamp wire harness. 2. Insert bulb into lamp so index notches on
bulb engage with bosses in lamp. 3. Hinge wire retainer clip over bulb base. 4. Engage wire clip to
hold bulb into lamp. 5. Install rear cover on fog lamp. 6. Install fog lamp on vehicle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations
Fog/Driving Lamp Relay: Locations
Instrument Panel Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Locations > Page 8660
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions
Fog/Driving Lamp Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8663
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8664
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8665
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8666
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8667
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8668
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8669
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8670
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8671
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8672
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8673
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8674
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8675
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8676
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8677
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8678
Fog/Driving Lamp Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8679
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8680
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8681
Fog/Driving Lamp Relay: Electrical Diagrams
Front Lighting (Part 2 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8682
Front Lighting (Part 3 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Fog/Driving Lamp > Fog/Driving Lamp Relay > Component Information >
Diagrams > Diagram Information and Instructions > Page 8683
Front Lighting (Part 6 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Description and Operation
Hazard Warning Flasher: Description and Operation
SYSTEM OPERATION
Combination Flasher
Without Daytime Running Lamp Module
Combination Flasher Location
The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning
functions and has been designed with internal relays to take advantage of low current switching
requirements in the vehicle. It is plugged into the Junction Block at position 4 where all wiring
associated with its operation is terminated. The Junction Block is adjacent to and left of the steering
column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker.
The combination flasher may be operated in its hazard warning mode either with or without the
ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit
must be completed to the module.
While the combination flasher is idle, there is no current drawn through the module. The device
does not become active until a signal ground circuit is supplied to either of the turn signal inputs or
the hazard warning input.
Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side
of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute
when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90
flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of
300 mA and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
drawing a maximum of 600 mA through the multi-function switch.
With Daytime Running Lamp Module
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Description and Operation > Page 8688
Junction Block Terminal Pins
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 and 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle. To gain access to the device, remove the lower steering
column cover and knee blocker.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side
of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute
when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90
flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA, and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL
Hazard Warning Flasher: Testing and Inspection Combination Flasher Diagnosis With DRL
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8691
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8692
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8693
Hazard Warning Flasher: Testing and Inspection Combination Flasher Diagnosis Without DRL
Combination Flasher Diagnosis Without DRL (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8694
Combination Flasher Diagnosis Without DRL (Part 2 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8695
Hazard Warning Flasher: Testing and Inspection With Daytime Running Lamps Module
Electronic Combination Flasher With DRL Circuit
Junction Block Terminal Call-Out With DRL
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC)
through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD.
This circuit (L09) is the only power feed to the combination-flasher/DRL.
The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8696
This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is
so equipped: Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil
The ignition input to the combo-flasher will draw typically 5 mA of current while active.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8697
Hazard Warning Flasher: Testing and Inspection Without Daytime Running Lamps Module
Electronic Combination Flasher Circuit
Junction Block Terminal Call-Out
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC)
through a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD.
This circuit (L09) is the only power feed to the combination-flasher/DRL.
The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D.
This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is
so equipped: Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Combination Flasher Diagnosis With DRL > Page 8698
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil
The ignition input to the combo-flasher will draw typically 5 mA of current while active.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Flasher > Component
Information > Testing and Inspection > Page 8699
Hazard Warning Flasher: Service and Repair
With/Without DRL Module
REMOVAL
1. Remove lower steering column cover. 2. Remove knee blocker. 3. Pull combination flasher from
junction block.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Hazard Warning Lamps > Hazard Warning Switch > Component
Information > Service and Repair
Hazard Warning Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Bulb > Component Information > Service and
Repair
Headlamp Bulb: Service and Repair
Headlamp Bulb
REMOVAL
1. Release hood latch and open hood. 2. From behind radiator closure panel, disengage wire
connector from back of headlamp bulb base. 3. Rotate headlamp bulb retaining ring counter
clockwise. 4. Disengage retaining ring from headlamp. 5. Pull headlamp bulb from back of
headlamp.
INSTALLATION
CAUTION: Do not touch the glass of halogen bulbs with fingers or other possibly oily surface,
reduced bulb life will result.
1. From behind radiator closure panel, insert headlamp bulb into back of headlamp. 2. Engage
retaining ring onto headlamp. 3. Rotate headlamp bulb retaining ring clockwise. 4. Engage wire
connector into headlamp bulb base. 5. Verify headlamp alignment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information >
Description and Operation
Headlamp Control Module: Description and Operation
GENERAL INFORMATION
Minor amounts of fogging may occur around the edges of the headlamp lens when exposed to
humid conditions. This is considered normal. The fogging will dissipate with increased ambient
temperature or headlamp usage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Control Module > Component Information >
Description and Operation > Page 8710
Headlamp Control Module: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. From inside engine compartment, remove nuts holding
headlamp module to radiator closure panel. 3. Remove screw holding top of module to closure
panel.
Headlamp Module
4. Separate headlamp module from radiator closure panel. 5. Disengage wire connectors from
back of headlamp module. 6. Separate headlamp module from vehicle.
INSTALLATION
1. Place headlamp module in position on vehicle. 2. Engage wire connectors into back of headlamp
module. 3. Place headlamp module in position on radiator closure panel. 4. Install nuts to hold
headlamp module to radiator closure panel. 5. Install screw to hold top of module to closure panel.
6. Verify headlamp operation and alignment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Dimmer Switch > Component Information >
Description and Operation
Headlamp Dimmer Switch: Description and Operation
GENERAL INFORMATION
The headlamp dimmer switch is incorporated into the multi-function (turn signal) switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams
Headlamp Switch: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Diagrams >
Page 8720
Headlamp Switch: Testing and Inspection
Headlamp Switch Test
Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test.
Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within
specifications replace as necessary.
The Chrysler Town and Country is available with optional Automatic Headlamps.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and
Repair > Headlight Switch
Headlamp Switch: Service and Repair Headlight Switch
Headlamp Switch
REMOVAL
1. Remove instrument cluster bezel. 2. Remove screws holding the headlamp switch bezel to
cluster bezel. 3. Disconnect the wire connectors from the headlamp switch and wire connector from
the power mirror switch. 4. Remove headlamp switch bezel from cluster bezel.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Headlamp > Headlamp Switch > Component Information > Service and
Repair > Headlight Switch > Page 8723
Headlamp Switch: Service and Repair Headlight Switch Lamp
Headlamp Switch Lamp
REMOVAL
1. Remove instrument cluster bezel. 2. Disconnect wire connectors. 3. Remove headlamp switch
bezel from instrument cluster bezel. 4. Rotate bulb socket counter clockwise one quarter turn. 5.
Pull bulb socket from headlamp switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8728
Horn Relay: Testing and Inspection
1. Remove horn relay.
Horn Relay
2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance.
If resistance not OK, replace relay. 3. Test for continuity between ground and terminal 85 of horn
relay.
a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground
when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as
necessary.
4. Using voltmeter, test voltage at:
a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM.
c. If incorrect voltage repair as necessary.
5. Insert a jumper wire between terminal 30 and 87 of the power distribution center.
a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn
Test.
Horns Will Not Sound Check horn fuse 6 in the Power Distribution Center and fuse 7 in the
Junction Block. If fuse is blown refer to FUSE BLOWN. If fuse is OK, refer to FUSE OK.
Fuse Blown 1. Verify condition of battery terminals and voltage. If battery connections and battery
charge is OK proceed to Step 2. 2. Using a voltmeter, test for battery voltage at both sides of horn
fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is
OK, on one side of fuse, the fuse is blown, proceed to Step 3.
3. Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If
amperage draw is greater than 20 amps without the
horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to
Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded
circuit exists between the horn relay and the horn. Proceed to step Step 5.
4. Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn
switch or circuit is shorted. If the amperage
draw does not drop to 0 amps, repair short at the Junction Block.
5. Disengage a wire connector from one of the horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does
not drop with both horns disconnected and the horn switch depressed, proceed to Step 6.
6. Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn
relay to ground. If continuity is detected, the
circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness.
Fuse OK 1. Remove the horn relay from the Junction Block. 2. Using a continuity tester, Depress
horn switch and test continuity from the X3 cavity of the horn relay to ground.
a. If continuity is detected, proceed to Step 3. b. If NO continuity, proceed to Step 4.
3. Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay
in the Junction Block.
a. If the horn sounds, replace the horn relay. b. If the horn does not sound, proceed to Step 4.
4. Remove airbag"horn pad from steering wheel. 5. Test continuity across horn switch connectors
with horn switch depressed.
a. If continuity is detected, repair open circuit between the relay and the horn switch. b. If NO
continuity, replace airbag cover.
6. Install horn relay into Junction Block. 7. Disengage wire connectors from horns.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Relay > Component Information > Locations > Page 8729
Horn And Connector
8. Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals
of the wire harness.
a. If voltage is detected, replace horns. b. If NO voltage, proceed to step Step 9.
9. With the horn switch depressed, test for voltage between the X2 circuit and ground.
a. If voltage OK, repair system ground at right cowl area. b. If NO voltage, repair open X2 circuit
between the relay and the horns.
Horns Sound Continuously
CAUTION: Continuous sounding of horns may cause relay to fail.
The horn switch (membrane) sometimes can be the cause without the switch being depressing. 1.
Remove the horn relay from the junction block. 2. Using a continuity tester, test continuity from the
X3 cavity of the horn relay to ground.
a. If continuity is detected, proceed to step Step 3. b. If NO continuity, replace the horn relay.
3. Remove the airbag/horn pad from the steering wheel and disengage horn connector. 4. Install
horn relay into junction block.
a. If horn does not sound, replace airbag cover/ horn pad. b. If horn sounds, repair grounded X3
circuit from junction block to clockspring in steering in steering column.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Horn > Horn Switch > Component Information > Service and Repair
Horn Switch: Service and Repair
The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Key Cylinder Lamp > Component Information > Diagrams > Page 8736
Key Cylinder Lamp: Service and Repair
Ignition Halo Lamp Bulb
REMOVAL
1. Remove steering column trim covers.
Ignition Halo Lamp Bulb
2. Rotate bulb socket counter clockwise one quarter turn. 3. Pull bulb socket from halo lamp.
INSTALLATION
1. Push bulb socket into halo lamp. 2. Rotate bulb socket clockwise one quarter turn. 3. Install
steering column trim covers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > License Plate Lamp > License Plate Bulb > Component Information >
Service and Repair
License Plate Bulb: Service and Repair
REMOVAL
1. Remove screws attaching license plate lamp lens to liftgate. 2. Remove license plate lamp lens
from lamp. 3. Rotate lamp socket counterclockwise one quarter turn.
License Plate Lamp Bulb
4. Pull socket from lens. 5. Pull bulb from socket.
INSTALLATION
1. Install bulb into socket. 2. Insert socket into lens. 3. Rotate lamp socket clockwise one quarter
turn. 4. Place license plate lamp lens in position in lamp. 5. Install screws attaching license plate
lamp lens. 6. Verify license plate lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Marker Lamp > Component Information > Testing and Inspection
Marker Lamp: Testing and Inspection
The dome lamps operate in conjunction with the Remote Keyless Entry system.
For additional diagnostic information on lamp operation controlled by Body Control Module (BCM),
refer to the Powertrain Management/Computer and Control Systems/Body Control Module (BCM).
Reading/dome Lamp Diagnosis
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Lamp Relay > Component Information >
Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Parking Lamp > Parking Light Bulb > Component Information > Service
and Repair
Parking Light Bulb: Service and Repair
REMOVAL
1. From under front wheelhouse, remove access cover behind park and turn signal lamp. 2.
Through access hole in wheelhouse, rotate park and turn signal socket counterclockwise one
quarter turn.
Park And Turn Signal Lamp Bulb
3. Pull socket from back of lamp. 4. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Through access hole in
wheelhouse, insert socket into back of lamp. 3. Rotate park and turn signal socket clockwise one
quarter turn. 4. Install access cover and verify lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations
Fog/Driving Lamp Relay: Locations
Instrument Panel Connections
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Locations > Page 8755
Junction Block
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions
Fog/Driving Lamp Relay: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8758
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8759
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8760
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8761
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8762
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8763
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8764
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8765
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8766
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8767
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8768
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8769
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8770
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8771
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8772
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8773
Fog/Driving Lamp Relay: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8774
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8775
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8776
Fog/Driving Lamp Relay: Electrical Diagrams
Front Lighting (Part 2 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8777
Front Lighting (Part 3 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Fog/Driving Lamp Relay >
Component Information > Diagrams > Diagram Information and Instructions > Page 8778
Front Lighting (Part 6 Of 8)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module >
Component Information > Description and Operation
Headlamp Control Module: Description and Operation
GENERAL INFORMATION
Minor amounts of fogging may occur around the edges of the headlamp lens when exposed to
humid conditions. This is considered normal. The fogging will dissipate with increased ambient
temperature or headlamp usage.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Control Module >
Component Information > Description and Operation > Page 8782
Headlamp Control Module: Service and Repair
REMOVAL
1. Release hood latch and open hood. 2. From inside engine compartment, remove nuts holding
headlamp module to radiator closure panel. 3. Remove screw holding top of module to closure
panel.
Headlamp Module
4. Separate headlamp module from radiator closure panel. 5. Disengage wire connectors from
back of headlamp module. 6. Separate headlamp module from vehicle.
INSTALLATION
1. Place headlamp module in position on vehicle. 2. Engage wire connectors into back of headlamp
module. 3. Place headlamp module in position on radiator closure panel. 4. Install nuts to hold
headlamp module to radiator closure panel. 5. Install screw to hold top of module to closure panel.
6. Verify headlamp operation and alignment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Headlamp Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 8789
Horn Relay: Testing and Inspection
1. Remove horn relay.
Horn Relay
2. Using ohmmeter, test between relay connector terminals 85 to 86 for 70 to 75 ohms resistance.
If resistance not OK, replace relay. 3. Test for continuity between ground and terminal 85 of horn
relay.
a. When the horn switch is not depressed, no continuity should be present. b. Continuity to ground
when horn switch is depressed. c. If continuity is not correct repair horn switch or wiring as
necessary.
4. Using voltmeter, test voltage at:
a. Terminals 30 and 86 of the horn relay to body ground. b. If NO voltage check fuse 7 of the BCM.
c. If incorrect voltage repair as necessary.
5. Insert a jumper wire between terminal 30 and 87 of the power distribution center.
a. If horn sounds replace relay. b. If the horn does not sound, install horn relay and refer to Horn
Test.
Horns Will Not Sound Check horn fuse 6 in the Power Distribution Center and fuse 7 in the
Junction Block. If fuse is blown refer to FUSE BLOWN. If fuse is OK, refer to FUSE OK.
Fuse Blown 1. Verify condition of battery terminals and voltage. If battery connections and battery
charge is OK proceed to Step 2. 2. Using a voltmeter, test for battery voltage at both sides of horn
fuse 7. If voltage is OK, on both sides of fuse, proceed to Fuse OK. If voltage is
OK, on one side of fuse, the fuse is blown, proceed to Step 3.
3. Using a suitable ammeter in place of the fuse, test amperage draw of the horn circuit. If
amperage draw is greater than 20 amps without the
horn switch depressed, a grounded circuit exists between the fuse and the horn relay. Proceed to
Step 4. If amperage draw is greater than 20 amps with the horn switch depressed, a grounded
circuit exists between the horn relay and the horn. Proceed to step Step 5.
4. Remove the horn relay from the Junction Block. If the amperage draw drops to 0 amps, the horn
switch or circuit is shorted. If the amperage
draw does not drop to 0 amps, repair short at the Junction Block.
5. Disengage a wire connector from one of the horns. If amperage drops and the connected horn
sounds, replace the faulty horn. If amperage does
not drop with both horns disconnected and the horn switch depressed, proceed to Step 6.
6. Using a continuity tester, with the horns disconnected test continuity of the X2 cavity of the horn
relay to ground. If continuity is detected, the
circuit is grounded between the Junction Block and the horns. Locate and repair pinched harness.
Fuse OK 1. Remove the horn relay from the Junction Block. 2. Using a continuity tester, Depress
horn switch and test continuity from the X3 cavity of the horn relay to ground.
a. If continuity is detected, proceed to Step 3. b. If NO continuity, proceed to Step 4.
3. Using a suitable jumper wire, jump across the fuse F62 cavity and the X2 cavity of the horn relay
in the Junction Block.
a. If the horn sounds, replace the horn relay. b. If the horn does not sound, proceed to Step 4.
4. Remove airbag"horn pad from steering wheel. 5. Test continuity across horn switch connectors
with horn switch depressed.
a. If continuity is detected, repair open circuit between the relay and the horn switch. b. If NO
continuity, replace airbag cover.
6. Install horn relay into Junction Block. 7. Disengage wire connectors from horns.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Horn Relay > Component
Information > Locations > Page 8790
Horn And Connector
8. Using a voltmeter, with the horn switch depressed test voltage across horn connector terminals
of the wire harness.
a. If voltage is detected, replace horns. b. If NO voltage, proceed to step Step 9.
9. With the horn switch depressed, test for voltage between the X2 circuit and ground.
a. If voltage OK, repair system ground at right cowl area. b. If NO voltage, repair open X2 circuit
between the relay and the horns.
Horns Sound Continuously
CAUTION: Continuous sounding of horns may cause relay to fail.
The horn switch (membrane) sometimes can be the cause without the switch being depressing. 1.
Remove the horn relay from the junction block. 2. Using a continuity tester, test continuity from the
X3 cavity of the horn relay to ground.
a. If continuity is detected, proceed to step Step 3. b. If NO continuity, replace the horn relay.
3. Remove the airbag/horn pad from the steering wheel and disengage horn connector. 4. Install
horn relay into junction block.
a. If horn does not sound, replace airbag cover/ horn pad. b. If horn sounds, repair grounded X3
circuit from junction block to clockspring in steering in steering column.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Relays and Modules - Lighting and Horns > Parking Lamp Relay >
Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8798
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8799
Brake Light Switch: Service Precautions
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8800
Brake Light Switch: Description and Operation
The stop lamp switch controls operation of the vehicles stop lamps. Also, if the vehicle is equipped
with speed control, the stop lamp switch will deactivate speed control when the brake pedal is
depressed.
The stop lamp switch controls operation of the right and left tail, stop and turn signal lamp and
Center High Mount Stop Lamp (CHMSL) lamp, by supplying battery current to these lamps.
The stop lamp switch controls the lamp operation by opening and closing the electrical circuit to the
stop lamps.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8801
Brake Light Switch: Adjustments
1. Remove stop lamp switch from its bracket by rotating it approximately 30° in a counter-clockwise
direction. 2. Disconnect wiring harness connector from stop lamp switch. 3. Hold stop lamp switch
firmly in one hand. Then using other hand, pull outward on the plunger of the stop lamp switch until
it has ratcheted out to
its fully extended position.
4. Install the stop lamp switch into the bracket using the following procedure. Depress the brake
pedal as far down as possible. Then while keeping
the brake pedal depressed, install the stop lamp switch into the bracket by aligning index key on
switch with slot at top of square hole in mounting bracket. When switch is fully installed in the
square hole of the bracket, rotate switch clockwise approximately 30° to lock the switch into the
bracket.
Stop Light Switch Location In Vehicle
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If too much force is used, damage to the vacuum booster, stop lamp switch or striker can
result.
5. Connect the wiring harness connector to the stop lamp switch. 6. Gently pull back on brake
pedal until the pedal stops moving. This will cause the switch plunger to ratchet backward to the
correct position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Brake Light Switch >
Component Information > Locations > Page 8802
Brake Light Switch: Service and Repair
REMOVAL
Stop Lamp Switch
1. Depress and hold the brake pedal while rotating stop lamp switch in a counter-clockwise
direction approximately 30°. 2. Pull the switch rearward and remove from its mounting bracket. 3.
Disconnect wiring harness connector from stop lamp switch.
INSTALLATION
NOTE: Prior to installing stop lamp switch into bracket, the plunger must be moved to its fully
extended position using procedure in Step 1.
1. Hold stop lamp switch firmly in one hand. Then using other hand, pull outward on the plunger of
the stop lamp switch until it has ratcheted out to
its fully extended position.
2. Connect the wiring harness connector to the stop lamp switch. 3. Mount the stop lamp switch
into the bracket using the following procedure. Depress the brake pedal as far down as possible.
Then install switch in
bracket by aligning index key on switch with slot at top of square hole in mounting bracket. When
switch is fully installed in bracket, rotate switch clockwise approximately 30° to lock switch into
bracket.
CAUTION: Do not use excessive force when pulling back on brake pedal to adjust the stop lamp
switch. If to much force is used, damage to the stop lamp switch or striker can result.
4. Gently pull back on brake pedal until the pedal stops moving. This will cause the switch plunger
to ratchet backward to the correct position.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 8811
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 8812
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 8813
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 8814
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 8815
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 >
Steering Wheel - Click/Rattle Sound > Page 8816
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8822
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8823
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8824
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8825
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8826
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Combination Switch >
Component Information > Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 >
Feb > 00 > Steering Wheel - Click/Rattle Sound > Page 8827
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Glove Box Lamp Switch >
Component Information > Service and Repair
Glove Box Lamp Switch: Service and Repair
REMOVAL
1. Open glove box door. 2. Using a trim stick, lightly pry glove box lamp/ switch from instrument
panel.
Glove Box Lamp And Switch
3. Disengage wire connector from glove box lamp and switch. 4. Remove glove box lamp and
switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Hazard Warning Switch >
Component Information > Service and Repair
Hazard Warning Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Dimmer Switch
> Component Information > Description and Operation
Headlamp Dimmer Switch: Description and Operation
GENERAL INFORMATION
The headlamp dimmer switch is incorporated into the multi-function (turn signal) switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams
Headlamp Switch: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Diagrams > Page 8840
Headlamp Switch: Testing and Inspection
Headlamp Switch Test
Using a Digital Multimeter, equipped with a diode test to perform the Headlamp Switch Test.
Switch position possibilities are open (no continuity), continuity, resistance value in ohms, or diode
test. Use the values in the third column to determine meter setting. If Headlamp Switch is not within
specifications replace as necessary.
The Chrysler Town and Country is available with optional Automatic Headlamps.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch
Headlamp Switch: Service and Repair Headlight Switch
Headlamp Switch
REMOVAL
1. Remove instrument cluster bezel. 2. Remove screws holding the headlamp switch bezel to
cluster bezel. 3. Disconnect the wire connectors from the headlamp switch and wire connector from
the power mirror switch. 4. Remove headlamp switch bezel from cluster bezel.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Headlamp Switch >
Component Information > Service and Repair > Headlight Switch > Page 8843
Headlamp Switch: Service and Repair Headlight Switch Lamp
Headlamp Switch Lamp
REMOVAL
1. Remove instrument cluster bezel. 2. Disconnect wire connectors. 3. Remove headlamp switch
bezel from instrument cluster bezel. 4. Rotate bulb socket counter clockwise one quarter turn. 5.
Pull bulb socket from headlamp switch.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Horn Switch > Component
Information > Service and Repair
Horn Switch: Service and Repair
The horn switch is molded into the airbag cover. The horn switch cannot be serviced separately.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Locations > Page 8850
Interior Light Switch: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Interior Light Switch >
Component Information > Locations > Page 8851
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams
Multi-Function Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 8855
Turn Signal Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Sensors and Switches - Lighting and Horns > Turn Signal Switch >
Component Information > Diagrams > Page 8856
Turn Signal Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Tail Lamp > Tail Light Bulb > Component Information > Service and
Repair
Tail Light Bulb: Service and Repair
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-Up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8870
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8871
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8872
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8873
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8874
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > Customer Interest for Combination Switch: > 19-09-99 > Feb > 00 > Steering Wheel Click/Rattle Sound > Page 8875
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound
Technical Service Bulletin # 19-09-99 Date: 000211
Steering Wheel - Click/Rattle Sound
NUMBER: 19-09-99
GROUP: Steering
EFFECTIVE DATE: Feb. 11, 2000
SUBJECT: Click/Rattle Sound In Area Of Steering Wheel
OVERVIEW: This bulletin involves checking steering column components for correct torque,
lubricating the shift lockout tab, modifying the clockspring and adding tape to the multifunction
switch and steering wheel.
MODELS: 1996 - 2000 (NS) Town & Country/Caravan/Voyager 1996 - 2000 (GS) Chrysler Voyager
(International Market)
SYMPTOM/CONDITION: A click/rattle sound may be heard coming from the area of the steering
wheel while the vehicle is in motion. The sound is associated with rotation of the steering wheel or
input from the road surface. It may be difficult to readily repeat the sound once it has occurred until
additional road input is experienced, such as running over an expansion strip.
DIAGNOSIS: If the vehicle operator describes the symptom above, perform the following Repair
Procedure.
PARTS REQUIRED:
AR NPN Tape, Foam 3M P/N 06375 or Equivalent
AR NPN Tape, Anti-Squeak 3M P/N 06356 or Equivalent
AR 05018626AA Grease, Damping
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE: Labor Operation No:
19-34-05-93 0.6 Hrs.
FAILURE CODE: XX - Service Adjustment
Repair Procedure
THIS REPAIR IS COMPATIBLE WITH DAIMLERCHRYSLER'S MOBILE SERVICE PROGRAM
AND DOES NOT REQUIRE HOISTS OR OTHER FULL SERVICE FACILITY SPECIAL
EQUIPMENT.
1. Make sure the front wheels of the vehicle are in the straight ahead position.
2. Disconnect and isolate the negative/ground battery cable.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 8881
Fig. 1
3. Remove the screws attaching the lower steering column cover and separate the cover from the
instrument panel (Figure 1).
4. Disconnect the parking brake release cable from the parking brake release lever.
Fig. 2
5. Remove the 10 bolts attaching the steering column cover liner to the instrument panel and
separate the liner from the instrument panel (Figure 2).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 8882
Fig. 3
6. Remove the key from the ignition switch and rotate the steering wheel to the left one half turn
until the steering wheel lock engages (Figure 3).
7. Remove the three screws attaching the air bag module to the steering wheel and lift the air bag
module from the steering wheel.
Fig. 4
8. Disconnect the wiring connectors from the air bag, horn switch wire and speed control switches.
Remove the wiring harness routing clip from the air bag module studs. If the vehicle is equipped
with steering wheel mounted radio controls disconnect the radio control wiring connector from the
clock spring (Figure 4).
9. Remove the steering wheel retaining nut from the steering column shaft.
10. Remove the steering wheel damper from the steering wheel.
CAUTION
DO NOT BUMP OR HAMMER ON THE STEERING COLUMN OR THE STEERING COLUMN
SHAFT WHEN REMOVING THE STEERING WHEEL.
WHEN INSTALLING THE STEERING WHEEL PULLER BOLTS IN THE STEERING WHEEL, DO
NOT THREAD THE BOLTS INTO THE STEERING WHEEL MORE THAN ONE HALF INCH. IF
THE BOLTS ARE THREADED INTO THE STEERING WHEEL MORE THAN ONE
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 8883
HALF INCH THE CLOCK SPRING WILL BE DAMAGED.
11. Remove the steering wheel from the steering column shaft using a steering wheel puller.
CAUTION
THE UPPER AND LOWER STEERING COLUMN SHROUDS ARE HELD TOGETHER USING
RETAINING CLIPS. WHEN SEPARATING AND REMOVING THE SHROUDS FROM THE
STEERING COLUMN BE CAREFUL NOT TO BREAK THE RETAINING CLIPS OFF THE
SHROUDS.
12. Remove the three screws attaching the upper and lower shrouds to the steering column and
separate the shrouds from the column.
13. Disconnect the vehicle wiring harness connectors from the clockspring assembly.
CAUTION
DO NOT ROTATE THE CLOCKSPRING AFTER IT IS REMOVED FROM THE MULTIFUNCTION
SWITCH.
14. Remove the clockspring from the multifunction switch.
Fig. 5
15. Check the tightness of the two tilt rack attaching screws, make sure they are torqued to 6 Nm
(50 in. lbs.), (Figure 5).
Fig. 6
16. Dab lubricant between the shift lock out tab/finger, pivot and bracket (Figure 6).
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 8884
Fig. 7
17. Use side cutter pliers to clip off the retention notch/hook portion of the alignment tangs on the
clockspring (Figure 7).
Fig. 8
18. Apply four pieces of foam tape to the crosshatched area of the multifunction switch (Figure 8).
Be sure the tape does not extend past the crosshatched area of the multifunction switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 8885
Fig. 9
19. Apply anti-squeak tape to the flats of the steering wheel hub casting (Figure 9).
20. Install the clockspring to the multitunction switch and connect it's wiring connector to the vehicle
harness connector.
21. Install the lower steering column shroud onto the steering column. Install and securely tighten
the screw attaching the lower shroud to the column.
22. Install the upper steering column shroud and securely tighten the two screws attaching the
upper to lower shroud.
CAUTION
DO NOT FORCE THE STEERING WHEEL ONTO THE STEERING COLUMN SHAFT. PULL THE
STEERING WHEEL DOWN ONTO THE SHAFT USING THE STEERING WHEEL RETAINING
NUT.
Fig. 10
23. Align the master splines on the steering wheel and the steering column shaft as well as the flats
on the steering wheel hub with the formations on the clockspring and install the wheel onto the
shaft. Wiring leads from the clock spring must be routed as shown in Figure 10.
24. Install the steering wheel damper as shown in Figure 4.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Combination Switch > Component Information >
Technical Service Bulletins > All Technical Service Bulletins for Combination Switch: > 19-09-99 > Feb > 00 > Steering
Wheel - Click/Rattle Sound > Page 8886
25. Install the steering wheel retaining nut and tighten it to 61 Nm (45 ft. lbs.).
26. Connect the clockspring wiring leads to the remote radio control connector, airbag, horn switch
and speed control switches as appropriate. Attach the wire routing clip to the studs on the airbag
module.
27. Install the airbag to the steering wheel and attach with three bolts. Tighten the bolts to 11 Nm
(100 in.lbs.).
28. Install the steering column cover liner to the lower instrument panel. Install and securely tighten
the 10 attaching bolts.
29. Install the parking brake release cable to the parking brake release lever in the lower steering
column cover.
30. Install the lower steering column cover on the lower instrument panel. Install and securely
tighten the attaching screws.
31. Connect the negative battery cable.
32. Set the clock to the correct time.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Locations
Combination Flasher Location
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions
Turn Signal Flasher: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8892
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8893
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8894
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8895
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8896
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8897
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8898
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8899
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8900
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8901
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8902
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8903
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8904
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8905
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8906
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8907
Turn Signal Flasher: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8908
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8909
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8910
Turn Signal Flasher: Connector Views
Junction Block Terminal Pins
Junction Block Terminal Call-Out With DRL
Junction Block Terminal Pins
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8911
Junction Block Terminal Call-Out
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8912
Turn Signal Flasher: Electrical Diagrams
Electronic Combination Flasher With DRL Circuit
Junction Block Terminal Call-Out With DRL
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Diagrams > Diagram Information and Instructions > Page 8913
Electronic Combination Flasher Circuit
Junction Block Terminal Call-Out
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL)
Turn Signal Flasher: Description and Operation Combination Flasher -- With Daytime Running
Lamps (DRL)
Combination Flasher Location
SYSTEM OPERATION
The turn signals are actuated with a lever on the left side of the steering column just ahead of the
steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to
the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns
the switch to the OFF position.
Lane change signaling is actuated by applying partial turn signal stalk movement toward the
direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is
released the stalk will spring back into the neutral position turning OFF the turn signal.
With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows
through the: Combination flasher
- Multi-function switch
- Turn indicator lamp
- Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn
signal ON.
FLASHER MODULE DESCRIPTION
The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and
hazard warning functions and has been designed with internal relays to take advantage of low
current switching requirements in the vehicle. It is plugged into the Junction Block at position 4,
where all wiring associated with its operation is terminated.
The Junction Block is adjacent to and left of the steering column of the vehicle.
To gain access to the flasher, remove the lower steering column cover and knee blocker.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8916
Junction Block Terminal Pins
FLASHER MODULE OPERATION
The Combination Flasher/DRL is a module providing turn signal, hazard warning, and daytime
running light functions, and has been designed with internal relays to take advantage of low current
switching requirements in the vehicle. It is plugged into the junction block at positions 3 and 4
where all wiring associated with its operation is terminated. The Junction Block is adjacent to and
left of the steering column of the vehicle. To gain access to the device, remove the lower steering
column cover and knee blocker.
The combination flasher/DRL may be operated in its hazard warning mode either with or without
the ignition circuit being active. However, in order to operate in the turn signal mode or the DRL
mode, the ignition circuit must be completed to the module.
While the combination flasher portion is idle, there is no current drawn through the module. The
device does not become active in the turn signal or hazard warning modes until a signal ground
circuit is supplied to either of the turn signal inputs or the hazard warning input. With the ignition
OFF, there is no current drawn through the module.
While the ignition is ON, the front turn signal filaments are illuminated steadily thus providing the
DRL function. The DRL function may be inhibited by applying a signal ground input from either the
park brake circuit or the headlamp relay activation circuit.
Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side
of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute
when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90
flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each could draw a maximum of
300 mA, and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
that could draw a maximum of 600 mA. through the multi-function switch.
Electronic Combination Flasher With DRL Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8917
Junction Block Terminal Call-Out With DRL
CIRCUIT OPERATION
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC)
through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD.
This circuit (L09) is the only power feed to the combination-flasher/DRL.
The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D.
This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is
so equipped: Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil
The ignition input to the combo-flasher will draw typically 5 mA of current while active.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8918
Turn Signal Flasher: Description and Operation Combination Flasher -- Without Daytime Running
Lamps (DRL)
Combination Flasher Location
SYSTEM OPERATION
The turn signals are actuated with a lever on the left side of the steering column just ahead of the
steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to
the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns
the switch to the OFF position.
Lane change signaling is actuated by applying partial turn signal stalk movement toward the
direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is
released the stalk will spring back into the neutral position turning OFF the turn signal.
With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows
through the: Combination flasher
- Multi-function switch
- Turn indicator lamp
- Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn
signal ON.
FLASHER MODULE DESCRIPTION
The Turn Signal/Hazard Warning Flasher is a module providing the vehicle with turn signal and
hazard warning functions and has been designed with internal relays to take advantage of low
current switching requirements in the vehicle. It is plugged into the Junction Block at position 4,
where all wiring associated with its operation is terminated.
The Junction Block is adjacent to and left of the steering column of the vehicle.
To gain access to the flasher, remove the lower steering column cover and knee blocker.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8919
Junction Block Terminal Pins
FLASHER MODULE OPERATION
The Turn Signal/Hazard Warning Flasher is a module providing turn signal, hazard warning
functions and has been designed with internal relays to take advantage of low current switching
requirements in the vehicle. It is plugged into the Junction Block at position 4 where all wiring
associated with its operation is terminated. The Junction Block is adjacent to and left of the steering
column of the vehicle.
To gain access to the device, remove the lower steering column cover and knee blocker.
The combination flasher may be operated in its hazard warning mode either with or without the
ignition circuit being active. However, in order to operate in the turn signal mode, the ignition circuit
must be completed to the module.
While the combination flasher is idle, there is no current drawn through the module. The device
does not become active until a signal ground circuit is supplied to either of the turn signal inputs or
the hazard warning input.
Typical flash rate for the flasher is 90 flashes per minute. When a lamp is burnt out for a given side
of the vehicle or a wire is open to a lamp, the flash rate will increase to 180 flashes per minute
when in the turn signal mode. When in the hazard warning signal mode the flash rate remains at 90
flashes per minute.
Turn signal inputs that actuate the flasher are low current grounds, each drawing a maximum of
300 mA and are provided to the flasher through the Junction Block from the multi-function switch
that is mounted to the steering column. The hazard warning signal input is a low current ground
drawing a maximum of 600 mA through the multi-function switch.
Electronic Combination Flasher Circuit
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8920
Junction Block Terminal Call-Out
CIRCUIT OPERATION
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness through. It originates under the hood in the Power Distribution Center (PDC)
through a 20 ampere fuse at position 15 (5th position from the upper end) and labeled HAZARD.
This circuit (L09) is the only power feed to the combination-flasher/DRL.
The ignition input of Pin 6, only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D.
This circuit feeds the combo-flasher and the following systems with Ignition voltage if the vehicle is
so equipped: Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil
The ignition input to the combo-flasher will draw typically 5 mA of current while active.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Combination Flasher -- With Daytime Running Lamps (DRL) > Page 8921
Turn Signal Flasher: Description and Operation Combination Flasher Operation
SYSTEM OPERATION
The turn signals are actuated with a lever on the left side of the steering column just ahead of the
steering wheel. The signals are automatically turned off by a canceling cam (two lobes molded to
the clock- spring mechanism). The cam comes in contact with the cancel actuator on the turn
signal (multi-function) switch assembly. Either cam lobe, pushing on the cancel actuator, returns
the switch to the OFF position.
Lane change signaling is actuated by applying partial turn signal stalk movement toward the
direction desired until the indicator lamps flashes in the instrument cluster. When the switch stalk is
released the stalk will spring back into the neutral position turning OFF the turn signal.
With the ignition switch ON and the turn signal switch stalk actuated left or right, current flows
through the: Combination flasher
- Multi-function switch
- Turn indicator lamp
- Front and rear turn signal bulbs.
A chime will sound after the vehicle has traveled a distance of approximately 0.5 Mile with the turn
signal ON.
Circuit Operation The turn signal and hazard flasher system used in this vehicle is controlled by the
combination flasher located in the junction block. On vehicles built for sale in Canada the Daytime
Running Lamp (DRL) module is part of the combination flasher.
Power for the combination flasher is supplied from two sources. One is a direct battery feed on
circuit L9. This circuit is HOT at all times and protected by a 20 Amp fuse located in cavity 19 of the
Power Distribution Center (PDC).
The other power source is a fuse battery feed from the ignition switch on circuit F20. This circuit is
HOT in the RUN position only and connects from the ignition switch to the combination flasher.
Power for the F20 circuit is supplied on circuit A22/A2. This circuit originates at the PDC and is
protected by a 40 Amp fuse located in cavity 2.
LEFT TURN SIGNALS
Circuit Operation When the operator selects the left turn signal, circuit L305 is connected to the Z1
ground circuit through the turn signal switch.
The combination flasher senses the position of the switch and supplies power to the L61 and L63
circuits.
Circuit L61 connects from the combination flasher to the left front turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the left cowl panel.
Circuit L63 connects from the combination flasher to the left rear turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced
and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to
the indicator lamp in the message center.
RIGHT TURN SIGNALS
Circuit Operation When the operator selects the right turn signal circuit L302 is connected to the Z1
ground circuit through the turn signal switch.
The combination flasher senses the position of the switch and supplies power to the L60 and L62
circuits.
Circuit L60 connects from the combination flasher to the right front turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the right cowl panel.
Circuit L62 connects from the combination flasher to the right rear turn signal lamp. Ground for the
lamp is supplied on circuit Z1 and terminates at the rear body ground. This circuit is also spliced
and provides an input to the Body Control Module (BCM) to indicate the turn signals are ON and to
the indicator lamp in the message center.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8922
Turn Signal Flasher: Testing and Inspection
Electronic Combination Flasher Circuit
Electronic Combination Flasher With DRL Circuit
The battery input (Pin 1), is brought into the Junction Block through the Electrical Distribution
Wiring (EDW) harness. It originates under the hood in the Power Distribution Center (PDC) through
a 20 ampere fuse at position 10 (9th position from the upper end) and labeled HAZARD. This
circuit (L09) is the only power feed to the combination-flasher/ DRL.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8923
Junction Block Terminal Call-Out
Junction Block Terminal Call-Out With DRL
The ignition input of Pin 6 (refer to Junction Block Terminal Call-Out and Junction Block Terminal
Call-Out with DRL tables) only senses that the ignition circuit is ON and does not supply current to
the module in a way that would power the system. This RUN/START circuit is brought into the
junction block to a 10 ampere fuse labeled TS BU LMP at the bottom right side. The circuit
designation out of the fuse is A22D. This circuit feeds the combo-flasher and the following systems
with Ignition voltage if the vehicle is so equipped:
- Back-Up Lamps
- Electrochromic Inside Rear view Mirror
- A/C Control Head
- Mini-Trip Computer
- ABS Module
- Front Blower Relay Coil
- Rear Blower Relay Coil
- AWD Solenoids
- Rear Window Defogger (EBL) Relay Coil The ignition input to the combo-flasher will draw typically
5 mA of current while active.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8924
Combination Flasher Diagnosis (Part 1 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8925
Combination Flasher Diagnosis (Part 2 Of 2)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8926
Combination Flasher Diagnosis With DRL (Part 1 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8927
Combination Flasher Diagnosis With DRL (Part 2 Of 3)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8928
Combination Flasher Diagnosis With DRL (Part 3 Of 3)
For diagnostic test procedures, refer to Combination Flasher Diagnosis tables.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Flasher > Component Information >
Description and Operation > Page 8929
Turn Signal Flasher: Service and Repair
REMOVAL
1. Remove lower steering column cover. 2. Remove knee blocker. 3. Pull combination flasher from
junction block.
INSTALLATION
1. Push combination flasher to junction block. 2. Install knee blocker. 3. Install lower steering
column cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Park and Turn Signal Lamp Bulb
Turn Signal Bulb: Service and Repair Park and Turn Signal Lamp Bulb
REMOVAL
1. From under front wheelhouse, remove access cover behind park and turn signal lamp. 2.
Through access hole in wheelhouse, rotate park and turn signal socket counterclockwise one
quarter turn.
Park And Turn Signal Lamp Bulb
3. Pull socket from back of lamp. 4. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Through access hole in
wheelhouse, insert socket into back of lamp. 3. Rotate park and turn signal socket clockwise one
quarter turn. 4. Install access cover and verify lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Lamp > Turn Signal Bulb > Component
Information > Service and Repair > Park and Turn Signal Lamp Bulb > Page 8935
Turn Signal Bulb: Service and Repair Tail, Stop, Turn Signal and Back-Up Lamp Bulb
REMOVAL
1. Release liftgate latch and open liftgate. 2. Remove screws holding tail, stop, turn signal and
back-up lamp to rear door opening trough. 3. Separate inner end of lamp from quarter panel. 4.
Disengage hook holding outer end of lamp to quarter panel opening. 5. Separate lamp from quarter
panel.
Tail, Stop, Turn Signal And Back-Up Lamp Bulb
6. Rotate lamp socket counterclockwise one quarter turn. 7. Pull socket from back of lamp.
Pull Bulb From Socket
8. Pull bulb from socket.
INSTALLATION
1. Align key on bulb base to groove in socket and insert bulb into socket. 2. Insert socket into back
of lamp. 3. Rotate lamp socket clockwise one quarter turn. 4. Engage hook to hold outer end of
lamp to quarter panel opening. 5. Place lamp in position on quarter panel. 6. Install screws to hold
lamp to rear door opening trough. 7. Verify tail, stop, turn signal and back-up lamp operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
Multi-Function Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
> Page 8939
Turn Signal Switch: Testing and Inspection
To test turn signal, headlamp beam select and optical horn portion of the multi-function switch:
1. Remove the multi-function switch, refer to removal procedures.
Turn Signal - Multi-Function Switch Pin Numbers
2. Using an ohmmeter check continuity reading between multi-function switch pins. Refer to the
above image for proper pin numbers and Turn
Signal Multi-Function Switch Test table.
TURN SIGNAL / MULTI-FUNCTION SWITCH TEST TABLE Switch position = Continuity Between
Left = 4 and 8 Right = 3 and 8 Hazard = 1 and 8 LO beam = 9 and 10 HI beam = 9 and 12
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Lighting and Horns > Turn Signals > Turn Signal Switch > Component Information > Diagrams
> Page 8940
Turn Signal Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood. 2. Disconnect and isolate battery negative cable.
3. Remove upper and lower steering column shrouds.
Turn Signal Multi-Function Switch
4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove screws
holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions
Heated Glass Element: Diagram Information and Instructions
Introduction
General Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8946
General Information
Chrysler wiring diagrams are designed to provide information regarding the vehicles wiring content.
In order to effectively use Chrysler wiring diagrams to diagnose and repair a Chrysler vehicle, it is
important to understand all of their features and characteristics.
Diagrams are arranged such that the power (B+) side of the circuit is placed near the top of the
page, and the ground (B-) side of the circuit is placed near the bottom of the page.
All switches, components, and modules are shown in the at rest position with the doors closed and
the key removed from the ignition.
Components are shown two ways. A solid line around a component indicates that the component is
complete. A dashed line around a component indicates that the component being shown is not
complete. Incomplete components have a reference number to indicate the page where the
component is shown complete.
It is important to realize that no attempt is made on the diagrams to represent components and
wiring as they appear on the vehicle. For example, a short piece of wire is treated the same as a
long one. In addition, switches and other components are shown as simply as possible, with regard
to function only.
Circuit Function
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8947
Circuit Identification Code Chart
All circuits in the diagrams use an alpha/numeric code to identify the wire and its function. To
identify which circuit code applies to a system, refer to the Circuit Identification Code Chart. This
chart shows the main circuits only and does not show the secondary codes that may apply to some
models.
Circuit Information
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8948
Wire Code Identification
Wire Color Code Chart
Each wire shown in the diagrams contains a code which identifies the main circuit, part of the main
circuit, gauge of wire, and color.
Connector Information
CAUTION: Not all connectors are serviced. Some connectors are serviced only with a harness. A
typical example might be the Supplemental Restraint System connectors. Always check parts
availability before attempting a repair.
IDENTIFICATION
In-line connectors are identified by a number, as follows: In-line connectors located on the engine compartment harness are C100 series numbers.
- Connectors located on the instrument panel harness are C200 series numbers.
- Connectors located on the body harness are C300 series numbers.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8949
- Jumper harness connectors are C400 series numbers.
- Grounds and ground connectors are identified with a "G" and follow the same series numbering
as the in-line connector.
Component Identification
Component connectors are identified by the component name instead of a number.
Connector Identification
Multiple connectors on a component use a C1, C2, etc. identifier.
Electrostatic Discharge (ESD) Sensitive Devices
Electrostatic Discharge Symbol
All Electrostatic Discharge (ESD) sensitive components are solid state and a symbol is used to
indicate this. When handling any component with this symbol, comply with the following procedures
to reduce the possibility of electrostatic charge build-up on the body and inadvertent discharge into
the component. If it is not known whether the part is ESD sensitive, assume that it is.
1. Always touch a known good ground before handling the part. This should be repeated while
handling the part, especially after sliding across a seat,
sitting down from a standing position, or walking a distance.
2. Avoid touching electrical terminals of the part, unless instructed to do so by a written procedure.
3. When using a voltmeter, be sure to connect the ground lead first. 4. Do not remove the part from
its protective packing until it is time to install the part. 5. Before removing the part from its package,
ground the package to a known good ground on the vehicle.
Fasteners
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8950
Shock Tower To Spring Minimum Clearance Area
CAUTION: At no time when servicing a vehicle, can a sheet metal screw, bolt, or other metal
fastener be installed in the strut tower to take the place of an original plastic clip. Also, NO holes
can be drilled into the front strut tower in the area shown in for the installation of any metal
fasteners into the strut tower.
Because of the minimum clearance in this area , installation of metal fasteners could damage the
coil spring coating and lead to a corrosion failure of the spring. If a plastic clip is missing, or is lost
or broken during servicing of a vehicle, replace it only with the equivalent part listed in the parts
catalog.
Fuses
CAUTION: When replacing a blown fuse, it is important to replace it with a fuse having the correct
amperage rating. The use of a fuse with a rating other than that indicated may result in an electrical
overload. If a properly rated fuse continues to blow, it indicates a problem that should be corrected.
Notes, Cautions and Warnings
Additional important information is presented in three ways: Notes, Cautions, and Warnings.
NOTES are used to help describe how switches or components operate to complete a particular
circuit. They are also used to indicate different conditions that may appear on the vehicle. For
example, an up-to and after condition.
CAUTIONS are used to indicate information that could prevent making an error that may damage
the vehicle.
WARNINGS provide information to prevent personal injury and vehicle damage. Below is a list of
general warnings that should be followed any time a vehicle is being serviced.
WARNING:
- ALWAYS WEAR SAFETY GLASSES FOR EYE PROTECTION.
- USE SAFETY STANDS ANYTIME A PROCEDURE REQUIRES BEING UNDER A VEHICLE.
- BE SURE THAT THE IGNITION SWITCH ALWAYS IS IN THE OFF POSITION, UNLESS THE
PROCEDURE REQUIRES IT TO BE ON.
- SET THE PARKING BRAKE WHEN WORKING ON ANY VEHICLE. AN AUTOMATIC
TRANSMISSION SHOULD BE IN PARK. A MANUAL TRANSMISSION SHOULD BE IN
NEUTRAL.
- OPERATE THE ENGINE ONLY IN A WELL-VENTILATED AREA.
- KEEP AWAY FROM MOVING PARTS WHEN THE ENGINE IS RUNNING, ESPECIALLY THE
FAN AND BELTS.
- TO PREVENT SERIOUS BURNS, AVOID CONTACT WITH HOT PARTS SUCH AS THE
RADIATOR, EXHAUST MANIFOLD(S), TAIL PIPE, CATALYTIC CONVERTER, AND MUFFLER.
- DO NOT ALLOW FLAME OR SPARKS NEAR THE BATTERY. GASES ARE ALWAYS
PRESENT IN AND AROUND THE BATTERY.
- ALWAYS REMOVE RINGS, WATCHES, LOOSE HANGING JEWELRY, AND LOOSE
CLOTHING.
Positive Temperature Coefficient
Positive Temperature Coefficient (PTC) devices are being used for circuit protection. These PTC's
act like a solid state fuse. They are located in the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8951
junction block, and are used to protect such items as: power door lock motors, power windows, and
various engine solenoids.
Positive Temperature Coefficient Symbol
A special symbol is used to identify these in the wiring diagrams.
Section Identification
Wiring Diagram Section Identification
The wiring diagrams are grouped into individual sections. If a component is most likely found in a
particular group, it will be shown complete (all wires, connectors, and pins) within that group. For
example, the Auto Shut Down Relay is most likely to be found in Group 30, so it is shown there
complete. It can, however, be shown partially in another group if it contains some associated
wiring.
Symbols
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8952
Wiring Diagram Symbols
International symbols are used throughout the wiring diagrams. These symbols are consistent with
those being used around the world.
Take-Outs
The abbreviation T/O is used in the component location section to indicate a point at which the
wiring harness branches out to a component.
How to Find System & Component Diagrams
When trying to find the diagram for a specific component or system, use the Group Index
information or the Alphabetic Index to Wiring Diagrams under Electrical
Whenever a reference exists to another sheet or figure, find the corresponding diagram using the
Group Index, Diagrams By Sheet Number, or Diagrams By Figure Number. The reference number
for the subsequent diagram will match a listed group shown.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8953
Connector and Terminal Replacement
1. Disconnect battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component. 3. Cut off the existing wire connector directly behind the insulator. Remove six
inches of tape from the harness. 4. Stagger cut all wires on the harness side at 1/2 inch intervals.
5. Remove 1 inch of insulation from each wire on the harness side.
Stagger Cutting Wires (Typical)
6. Stagger cut the matching wires on the repair connector assembly in the opposite order as was
done on the harness side of the repair. Allow extra
length for soldered connections. Check that the overall length is the same as the original.
7. Remove 1 inch of insulation from each wire. 8. Place a piece of heat-shrink tubing over one side
of the wire. Be sure the tubing will be long enough to cover and seal the entire repair area.
Wire Repair
9. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
10. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2). 11. Twist the wires together (Example 3). 12. Solder the connection together using rosin core
solder only. Do not use acid core solder. 13. Center the heat-shrink tubing over the joint and heat
using a heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
14. Repeat steps 8 through 13 for each wire. 15. Re-tape the wire harness starting 1-1/2 inches
behind the connector and 2 inches past the repair. 16. Re-connect the repaired connector. 17.
Connect the battery and test all affected systems.
Connector Replacement
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8954
1. Disconnect the battery. 2. Disconnect the connector (that is to be repaired) from its mating
half/component.
Connector Locking Wedge
3. Remove the connector locking wedge, if required.
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Reset the terminal locking tang, if it has one. 6. Insert the removed wire in the same cavity on
the repair connector. 7. Repeat steps 4 through 6 for each wire in the connector, being sure that all
wires are inserted into the proper cavities. 8. Insert the connector locking wedge into the repaired
connector, if required. 9. Connect the connector to its mating half/component.
10. Connect the battery and test all affected systems.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8955
Diode Replacement
Diode Identification
1. Disconnect the battery. 2. Locate the diode in the harness and remove the protective covering.
3. Remove the diode from the harness, pay attention to the current flow direction. 4. Remove the
insulation from the wires in the harness. Only remove enough insulation to solder in the new diode.
5. Install the new diode in the harness, making sure current flow is correct. 6. Solder the connection
together using rosin core solder only. Do not use acid core solder. 7. Tape the diode to the harness
using electrical tape, making sure the diode is completely sealed from the elements. 8. Re-connect
the battery and test affected systems.
Terminal Replacement
1. Disconnect the battery. 2. Disconnect the connector being repaired from its mating
half/component.
Connnector Locking Wedge Tab (Typical)
3. Remove the connector locking wedge, if required.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8956
Terminal Removal
Terminal Removal Using Special Tool
4. Position the connector locking finger away from the terminal using the proper pick from Special
Tool Kit 6680. Pull on the wire to remove the
terminal from the connector.
5. Cut the wire 6 inches from the back of the connector. 6. Remove 1 inch of insulation from the
wire on the harness side. 7. Select a wire from the terminal repair assembly that best matches the
color of the wire being repaired. 8. Cut the repair wire to the proper length and remove 1 inch of
insulation. 9. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will
be long enough to cover and seal the entire repair area.
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8957
10. Spread the strands of the wire apart on each part of the exposed wires (Example 1). 11. Push
the two ends of wire together until the strands of wire re close to the insulation (Example 2). 12.
Twist the wires together (Example 3). 13. Solder the connection together using rosin core solder
only. Do not use acid core solder. 14. Center the heat-shrink tubing over the joint and heat using a
heat gun. Heat the joint until the tubing is tightly sealed and sealant comes out of both
ends of the tubing.
15. Insert the repaired wire into the connector. 16. Install the connector locking wedge, if required
and re-connect the connector to its mating half/component. 17. Re-tape the wire harness starting
1-1/2 inches behind the connector and 2 inches past the repair. 18. Connect the battery and test all
affected systems.
Terminal/Connector Repair-Augat Connectors
1. Disconnect battery 2. Disconnect the connector from its mating half/component.
Augat Connector Repair
3. Push down on the yellow connector locking tab to release the terminals.
Using Special Tool 6932
4. Using Special Tool 6932, push the terminal to remove it from the connector. 5. Repair or replace
the connector or terminal as necessary 6. When re-assembling the connector, the locking wedge
must be placed in the locked position to prevent terminal push out.
Terminal/Connector Repair-Molex Connectors
1. Disconnect the battery. 2. Disconnect the connector from its mating half/component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8958
Molex Connector Repair
3. Insert the terminal releasing special tool 6742 into the terminal end of the connector.
Using Special Tool 6742
4. Using special tool 6742, release the locking fingers on the terminal. 5. Pull on the wire to remove
it from the connector. 6. Repair or replace the connector or terminal, as necessary.
Wiring Repair
Wire Repair
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8959
When replacing or repairing a wire, it is important that the correct gauge be used as shown in the
wiring diagrams. The wires must also be held securely in place to prevent damage to the insulation.
1. Disconnect the battery negative cable.
2. Remove 1 inch of insulation from each end of the wire.
3. Place a piece of heat-shrink tubing over one side of the wire. Be sure the tubing will be long
enough to cover and seal the entire repair area.
4. Spread the strands of the wire apart on each part of the exposed wires (Example 1).
5. Push the two ends of wire together until the strands of wire are close to the insulation (Example
2).
6. Twist the wires together (Example 3).
7. Solder the connection together using rosin core solder only. Do not use acid core solder.
8. Center the heat-shrink tubing over the joint and heat using a heat gun. Heat the joint until the
tubing is tightly sealed and sealant comes out of both
ends of the tubing.
9. Secure the wire to the existing ones to prevent chafing or damage to the insulation.
10. Connect the battery and test all affected systems.
Special Tools
Probing Tool Package 6807
Terminal Pick 6680
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8960
Terminal Removing Tool 6932
Terminal Removing Tool 6934
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8961
Heated Glass Element: Diagnostic Aids
Intermittent and Poor Connections
Most intermittent electrical problems are caused by faulty electrical connections or wiring. It is also
possible for a sticking component or relay to cause a problem. Before condemning a component or
wiring assembly check the following items.
- Connectors are fully seated
- Spread terminals, or terminal push out
- Terminals in the wiring assembly are fully seated into the connector/component and locked in
position
- Dirt or corrosion on the terminals. Any amount of corrosion or dirt could cause an intermittent
problem
- Damaged connector/component casing exposing the item to dirt and moisture
- Wire insulation that has rubbed through causing a short to ground
- Some or all of the wiring strands broken inside of the insulation covering.
- Wiring broken inside of the insulation
Troubleshooting Tests
Before beginning any tests on a vehicle's electrical system, use the wiring diagrams to study the
circuit. Also refer to Troubleshooting Wiring Problems section.
Testing For Voltage
Testing For Voltage
1. Connect the ground lead of a voltmeter to a known good ground. 2. Connect the other lead of
the voltmeter to the selected test point. The vehicle ignition may need to be turned ON to check
voltage. Refer to the
appropriate test procedure.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8962
Testing For Continuity
Testing For Continuity
1. Remove the fuse for the circuit being checked or disconnect the battery. 2. Connect one lead of
the ohmmeter to one side of the circuit being tested. 3. Connect the other lead to the other end of
the circuit being tested. Low or no resistance means good continuity.
Testing For A Short To Ground
1. Remove the fuse and disconnect all items involved with the fuse. 2. Connect a test light or a
voltmeter across the terminals of the fuse. 3. Starting at the fuse block, wiggle the wiring harness
every 6 to 8 Inches and watch the voltmeter/test light. 4. If the voltmeter registers voltage or the
test light glows, there is a short-to-ground in that general area of the wiring harness.
Testing For A Short-to-ground On Fuses Powering Several Loads
1. Refer to the wiring diagrams and disconnect or isolate all items on the fuse circuit. 2. Replace
the blown fuse. 3. Supply power to the fuse by turning ON the ignition switch or re-connecting the
battery. 4. Start connecting the items in the fuse circuit, one at a time. When the fuse blows, the
circuit with the short-to-ground has been isolated.
Testing For Voltage Drop
Testing For Voltage Drop
1. Connect the positive lead of the voltmeter to the side of the circuit closest to the battery. 2.
Connect the other lead of the voltmeter to the other side of the switch or component.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Diagram
Information and Instructions > Page 8963
3. Operate the item. 4. The voltmeter will show the difference in voltage between the two points.
Troubleshooting Tools
TROUBLESHOOTING TOOLS
When diagnosing a problem in an electrical circuit, there are several common tools necessary.
These tools are listed and explained below.
- Jumper Wire - This is a test wire used to connect two points of a circuit. It can be used to bypass
an open in a circuit.
WARNING: NEVER USE A JUMPER WIRE ACROSS A LOAD, SUCH AS A MOTOR,
CONNECTED BETWEEN A BATTERY FEED AND GROUND.
- Voltmeter - This instrument is used to check for voltage on a circuit. Always connect the black
lead to a known good ground and the red lead to the positive side of the circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking voltages in these circuits, use a meter with a 10 megohm or greater impedance.
- Ohmmeter - This instrument is used to check the resistance between two points of a circuit. Low
or no resistance in a circuit can mean good continuity or a shorted circuit.
CAUTION: Most of the electrical components used in today's vehicle are solid state. When
checking resistance in these circuits, use a meter with a 10 megohm or greater impedance. In
addition, be sure the power is disconnected from the circuit. Circuits that are powered-up by the
vehicle electrical system can cause damage to the equipment and provide false readings.
Probing Tool
- Probing Tools - These tools are used for probing terminals in connectors. Select the proper size
tool from Special Tool Package 6807 and insert it into the terminal being tested. Use the other end
of the tool to insert the meter probe.
Troubleshooting Wiring Problems
When troubleshooting wiring problems there are six steps which can aid in the procedure. The
steps are listed and explained below. Always check for non-factory items added to the vehicle
before doing any diagnosis. If the vehicle is equipped with these items, disconnect them to verify
these add-on items are not the cause of the problem.
1. Verify the problem.
2. Verify any related symptoms. Do this by performing operational checks on components that are
in the same circuit. Refer to the wiring diagrams.
3. Analyze the symptoms. Use the wiring diagrams to determine what the circuit is doing, where the
problem most likely is occurring and where the
diagnosis will continue.
4. Isolate the problem area.
5. Repair the problem.
6. Verify proper operation. For this step check for proper operation of all items on the repaired
circuit. Refer to the wiring diagrams.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page
8964
Heated Glass Element: Description and Operation
INTRODUCTION
Rear Window Defogger
Heated Windshield Wiper De-icer
The electrically heated Rear Window Defogger, Heated Power Side View Mirrors, and Heated
Windshield Wiper De-icer is available on NS vehicles.
The Rear Window Defogger system consists of two vertical bus bars linked by a series of grid lines
on the inside surface of the rear window. The electrical circuit consists of the rear defogger switch
in the HVAC and a relay with timer switch to turn OFF the system after ten minutes. The main feed
circuit is protected by fuse one (40 amp) in the Junction Block. The rear defogger switch and relay
also activates the heated power side view mirrors and heated windshield wiper de-icer. The HVAC
rear defogger switch is protected by fuse ten (10 amp) in the Junction Block. The heated mirror
circuit is protected by fuse 12 (10 amp) in the junction block. The heated windshield wiper de-icer
circuit is protected by fuse 21 (25 amp) in the Junction Block.
The Heated Windshield Wiper Deicer is also activated when the DEFROST mode is selected on
the HVAC. In the DEFROST mode the rear defogger relay/timer is bypassed, the heated
windshield wiper de-icer will stay ON until the another mode is selected.
CAUTION: Since grid lines can be damaged or scraped off with sharp instruments, care should be
taken in cleaning the glass or removing foreign materials, decals or stickers. Normal glass cleaning
solvents or hot water used with rags or toweling is recommended.
SYSTEM OPERATION
HVAC Mounted Switch
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Diagrams > Page
8965
HVAC Control Panel/Rear Window Defogger Switch
The rear window defogger switch is integrated into the HVAC. An LED indicator will illuminate when
the switch is activated. The switch energizes the timing circuit and activates the rear window
defogger relay. The relay controls the current to flow to the grids of the rear window defogger,
heated power side view mirrors and the heated windshield wiper de-icer. The defogger relay will be
on for approximately 10 minutes or until the control switch or ignition is turned off.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and
Inspection > Detecting Breaks in Rear Window Defogger Grid
Heated Glass Element: Testing and Inspection Detecting Breaks in Rear Window Defogger Grid
Grid Line Test
The horizontal grid lines and vertical bus bar lines printed and baked on inside surface of the
window glass makes up an electrical parallel circuit. The electrically conductive lines are composed
of a silver ceramic material which when baked on glass becomes bonded to the glass and is highly
resistant to abrasion. It is possible, however, that a break may exist or occur in an individual grid
line resulting in no current flow through the line. To detect breaks in grid lines, the following
procedure is required:
1. Turn ignition and rear window defogger control switch ON. The indicator light should come on. 2.
Using a DC voltmeter with 0 - 15 Volt range, contact vertical bus bar connecting grid lines on
passenger side of vehicle at terminal A with
negative lead of voltmeter. With positive lead of voltmeter, contact vertical bus bar on driver side of
vehicle at terminal B. The voltmeter should read 10 - 14 Volts.
3. With negative lead of voltmeter, contact a good body ground point. The voltage reading should
not change. A different reading indicates a poor
ground connection.
4. Connect negative lead of voltmeter to terminal A on passenger side bus bar and touch each grid
line at Mid-Point with positive lead. A reading of
approximately 6 Volts indicates a line is good. A reading of 0 Volts indicates a break in line
between Mid-Point C and terminal B. A reading of 10 - 14 Volts indicates a break between
Mid-Point C and ground terminal A. Move toward break and voltage will change as soon as break
is crossed.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and
Inspection > Detecting Breaks in Rear Window Defogger Grid > Page 8968
Heated Glass Element: Testing and Inspection Defogger System Testing
Electrically heated rear window defogger or the heated windshield wiper deicer operation can be
checked on the vehicle in the following manner:
1. Turn the ignition switch to the ON position. 2. Using a ammeter on the battery, turn the rear
defogger control switch to the ON position, a distinct increase in amperage draw should be noted.
3. The rear window defogger or the heated windshield wiper deicer operation can be checked by
feeling the glass. A distinct difference in
temperature between the grid lines and adjacent clear glass can be detected in 3 to 4 minutes of
operation.
Grid Line Test
4. Using a DC voltmeter contact terminal B with the negative lead, and terminal A with the positive
lead. The voltmeter should read 10 - 14 Volts. 5. Indicator light illumination means that there is
power available at the switch only and does not necessarily verify system operation. 6. If turning
the defogger switch ON, no distinct current draw on the ammeter the problem should be isolated in
the following manner:
- Confirm that ignition switch is ON.
- Ensure that the heated rear window or the heated windshield wiper deicer feed pigtail is
connected to the wiring harness and that the ground pigtail is in fact grounded.
- Ensure that the proper fuse in the Junction Block is OK.
7. When the above steps have been completed and the system is still inoperative, one or more of
the following is defective:
- HVAC switch
- Rear window defogger relay in the relay bank.
- Check for loose connector or a wire pushed out of connector.
- Rear window or the windshield grid lines (all grid lines would have to be broken, or one of the feed
pigtails not connected to the bus bar, for no ammeter deflection).
8. If turning the switch ON produces severe voltmeter deflection, the circuit should be closely
checked for a shorting condition. 9. If the system operation has been verified but indicator LED
does not light, replace switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Heated Glass Element > Component Information > Testing and
Inspection > Page 8969
Heated Glass Element: Service and Repair
WARNING: REPAIR KIT MAY CAUSE SKIN OR EYE IRRITATION. CONTAINS EPOXY RESIN
AND AMINE TYPE HARDENER, HARMFUL IF SWALLOWED. AVOID CONTACT WITH SKIN
AND EYES FOR SKIN, WASH AFFECTED AREAS WITH SOAP AND WATER. DO NOT TAKE
INTERNALLY. IF TAKEN INTERNALLY, INDUCE VOMITING; CALL A PHYSICIAN
IMMEDIATELY. IF IN CONTACT WITH EYES, FLUSH WITH PLENTY OF WATER. USE WITH
ADEQUATE VENTILATION DO NOT USE NEAR FIRE OR FLAME. CONTENTS CONTAINS 3%
FLAMMABLE SOLVENTS. KEEP OUT OF REACH OF CHILDREN.
The repair for the front windshield or the rear window grids are the same. The repair of grid lines
and replacement of the terminal is possible using the Mopar® Repair Package or equivalent.
1. Clean area surrounding grid line or terminal by gently rubbing area with steel wool. 2. Wipe area
with clean cloth soaked in alcohol or similar solvent. It is necessary that all contaminants be
removed from repair area. 3. Remove package separator clamp and mix plastic conductive epoxy
thoroughly.
4. For grid line, mark off area to be repaired with masking tape. 5. Apply conductive epoxy through
slit in masking tape. Overlap both ends of the break. 6. For a terminal replacement, apply a thin
layer of epoxy to area where terminal was fastened. 7. Apply a thin layer of epoxy on terminal and
place terminal on desired location. To prevent terminal from falling off use a wooden wedge to
secure
it.
8. Carefully remove masking tape from grid line.
CAUTION: Do not allow the laminated windshield glass surface to exceed 82 °C (180 °F) or the
glass may fracture. The rear window glass surface should not exceed 204 °C (400 °F).
9. Allow epoxy to cure 24 hours at room temperature.
10. After epoxy is properly cured remove wedge from terminal and check the operation of the rear
window defogger.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection
Power Window Switch: Testing and Inspection
Power Window and Vent Switch Test
1. Remove the driver or passenger door power window switch and bezel assembly from door trim
panel.
Power Window Master Switch Connector
Driver Door Power Window Switch Test
2. Using an ohmmeter, Test driver door switch for continuity.
* MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN
PINS 11 AND 6
Passenger Door Power Window Switch
3. Test passenger door switch for continuity.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Sensors and Switches - Windows and Glass > Power Window Switch >
Component Information > Testing and Inspection > Page 8974
4. If the results are not OK, replace the switch.
The driver door power window switch has a Auto-Down feature. The switch is equipped with two
detent positions when actuating the power window OPEN. The first detent position allows the
window to roll down and stop when the switch is released. The second detent position actuates an
integral express roll down relay that rolls the window down after the switch is released. When the
express down relay senses an amperage spike (motor pushing against down stop) in the feed
circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the
switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an
amperage spike will cause the switch to disconnect after approximately 11 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Motor > Front Door Window Motor >
Component Information > Service and Repair
Front Door Window Motor: Service and Repair
WARNING: DO NOT HAVE ANY HANDS OR FINGERS IN SECTOR GEAR AREA WHERE THEY
CAN BE PINCHED BY SMALL MOVEMENTS OF REGULATOR LINKAGE.
REMOVAL 1. Tape the window in its existing position to remove its weight from the regulator
system. 2. Cut and remove the tie wrap at the window motor. Its no longer required. 3. Disconnect
window motor wire connector from door harness. 4. Remove screws and nuts holding window
motor to the inner panel. 5. Remove the motor from the door inner panel, let it hang from the
cables. 6. With the cables still attached to the failed motor, Install the replacement motor to the
door inner panel. Tighten down the screws and nuts to 3.4 to
4.5 N.m ( 30 to 40 in. lbs.) of torque.
7. Separate the failed motor from regulator by:
- Removing the drum cover plate.
Power Window Motor Removal
- Lift the cable guide off the motor, the drum with cables, will be lifted off simultaneously.
CAUTION: Do not allow the drum to separate from the cable guide, by dropping drum or letting the
cables unwind.
INSTALLATION 1. Install the cable guide and drum into the replacement motor.
CAUTION: The drum may require a slight rotation to install onto the motor drive shaft. Rotate the
drum with the use of needle nose pliers or a similar tool. If, the drum does not align with the motor
shaft by a slight rotation, then, the glass should be lowered a small amount approximately 1 to 2
inches. The drum will rotate when the glass is lowered. Lowering the glass will require assistance
of a second person.
2. Install the replacement cover plate onto the replacement motor. Crimp toy tabs. 3. Connect the
wiring harness to the window motor connector. 4. Remove the tape holding the window in place
and test window operation.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection
Power Window Switch: Testing and Inspection
Power Window and Vent Switch Test
1. Remove the driver or passenger door power window switch and bezel assembly from door trim
panel.
Power Window Master Switch Connector
Driver Door Power Window Switch Test
2. Using an ohmmeter, Test driver door switch for continuity.
* MUST TEST WITH B+ ON PIN 9 AND GROUND ON PIN 13 FOR CONTINUITY BETWEEN
PINS 11 AND 6
Passenger Door Power Window Switch
3. Test passenger door switch for continuity.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Windows > Power Window Switch > Component Information > Testing
and Inspection > Page 8983
4. If the results are not OK, replace the switch.
The driver door power window switch has a Auto-Down feature. The switch is equipped with two
detent positions when actuating the power window OPEN. The first detent position allows the
window to roll down and stop when the switch is released. The second detent position actuates an
integral express roll down relay that rolls the window down after the switch is released. When the
express down relay senses an amperage spike (motor pushing against down stop) in the feed
circuit, current is turned off to the motor. The AUTO feature can be cancelled by actuating the
switch UP or DOWN while window is in motion. Failure of the electronic switch to detect an
amperage spike will cause the switch to disconnect after approximately 11 seconds.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair
Window Regulator: Service and Repair
REMOVAL
1. Remove door trim panel and water shield. 2. Remove door glass retaining clips and allow glass
to rest on bottom of door. 3. If equipped, disengage wire connector from power window motor.
Front Door Glass Window Lift Guides
4. Loosen screws holding front and rear window lift guides to inner door panel. 5. Separate screw
heads on lift guides from key hole slots in inner door panel. 6. Loosen screws holding regulator to
inner door panel.
7. Remove regulator from inner door panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Page 8987
Front Door Window Regulator
8. Extract rear lift guide through inner door panel access hole. 9. Extract front lift guide through
access hole.
INSTALLATION
1. Insert front lift guide through access hole.
Front Door Window Regulator
2. Insert rear lift guide through access hole. 3. Place window regulator in position on inner door
panel. 4. Place screw heads on guide rails in position through key hole slots in inner door panel. 5.
Tighten screws to hold regulator to inner door panel. 6. Place screw heads on lift guides in position
through key hole slots in inner door panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Windows and Glass > Windows > Window Regulator > Component Information > Service and
Repair > Page 8988
Front Door Glass Window Lift Guides
7. Tighten screws to hold front and rear window lift guides to inner door panel. 8. If equipped,
engage wire connector into power window motor. 9. Install door glass.
10. Verify door glass alignment and operation. 11. Install water shield and door trim panel.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Relays and Modules - Wiper and Washer Systems > Wiper
Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Washer
Fluid Level Switch > Component Information > Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Testing and Inspection
Windshield Washer Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch.
Windshield Wiper And Washer - Multi Function Switch Test
2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers.
Switch Position = Resistance Value Between
OFF = 6 AND 7 - MAX 1.0 Ohms
Delay Position
1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6
AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256
Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5
Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems >
Windshield Washer Switch > Component Information > Testing and Inspection > Page 9001
Windshield Washer Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Turn Signal Multi-Function Switch
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove
screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection
Wiper Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch.
Windshield Wiper And Washer - Multi Function Switch Test
2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers.
Switch Position = Resistance Value Between
OFF = 6 AND 7 - MAX 1.0 Ohms
Delay Position
1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6
AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256
Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5
Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Sensors and Switches - Wiper and Washer Systems > Wiper
Switch > Component Information > Testing and Inspection > Page 9005
Wiper Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Turn Signal Multi-Function Switch
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove
screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Washer Fluid Level Switch > Component Information >
Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information >
Locations > Rear Window Washer
Rear Wiper Motor
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information >
Locations > Rear Window Washer > Page 9013
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams
> Front
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Motor > Component Information > Diagrams
> Front > Page 9016
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Locations
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Pump > Component Information >
Locations > Page 9020
Windshield Washer Pump: Diagrams
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair
Windshield Washer Reservoir: Service and Repair
REMOVAL
1. Hoist and support vehicle on safety stands. 2. Remove right front wheel. 3. Remove front
wheelhouse splash shield.
Windshield Washer Bottle
4. Disconnect wire connectors from the windshield and rear window washer pumps. 5. If washer
bottle has fluid in it place a suitable drain pan under the hose connections.
Front Washer Hose
6. Disconnect front washer hose at front wiper unit in the engine compartment. The front hose will
be removed with the bottle.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Reservoir > Component Information >
Service and Repair > Page 9024
Rear Washer Hose Routing
7. Disconnect hose from rear washer pump nipple. 8. Allow washer bottle to drain. 9. Remove
screws holding washer bottle to front fender support and remove bottle.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection
Windshield Washer Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch.
Windshield Wiper And Washer - Multi Function Switch Test
2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers.
Switch Position = Resistance Value Between
OFF = 6 AND 7 - MAX 1.0 Ohms
Delay Position
1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6
AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256
Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5
Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Windshield Washer Switch > Component Information > Testing
and Inspection > Page 9028
Windshield Washer Switch: Service and Repair
WARNING: BEFORE SERVICING A STEERING COLUMN EQUIPPED WITH AN AIRBAG REFER
TO AIR BAGS AND SEAT BELTS FOR SAFE SERVICE PROCEDURES.
REMOVAL 1. Release hood latch and open hood.
Turn Signal Multi-Function Switch
2. Disconnect and isolate battery negative cable. 3. Remove upper and lower steering column
shrouds. 4. Disconnect wire connector from back of turn signal multi-function switch. 5. Remove
screws holding turn signal switch to steering column adapter collar. 6. Remove turn signal switch.
INSTALLATION For Installation, reverse the above procedures. Verify switch operation by placing the control stalk
in either the right or left position and turning the steering wheel to ensure the automatic cancellation
of the switch.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Adjustments
Wiper Arm: Adjustments
1. Verify wiper blade element condition and wiper arm spring tension. Run wipers in low speed
mode while applying water to the windshield.
Observe the wiper blade that is chattering or skipping across the windshield. If the wiper element is
not rolling over when the wiper direction reverses, align the wiper arm. The extension bar portion of
the wiper arm must be twisted in the proper direction to allow the wiper element to roll over when
the direction reverses.
2. Place two small adjustable wrenches placed 50 mm (2 in.) apart on the wiper arm extension rod.
3. Twist the extension rod slightly in the opposite direction that the element is laying on the
windshield while holding the wrench closest to the pivot
stationary.
4. Repeat step Step 1, and align as necessary until wiper stops chattering and wipes the
windshield clear.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Arm
Wiper Arm: Service and Repair Wiper Arm
CAUTION: The Driver side wiper arm must be parked above the passenger side. Failure to do so
will result in damage to the arms, blades or system.
REMOVAL 1. Disengage the clip holding outside end of the wiper arm pivot cover to the wiper arm.
2. Lift the arm cap upward. 3. Remove the nut holding wiper arm to the wiper pivot.
Wiper Arm Removal
4. Using a suitable two jaw puller, separate the wiper arm from the wiper pivot.
INSTALLATION 1. Verify that the wiper motor and linkage are in the park position.
Wiper Arm Adjustment
2. Place the wiper arm in position over the wiper pivot. Refer to Alignment. 3. Install the nut to hold
the wiper arm to the wiper pivot. Tighten nut to 35 N.m (26 ft. lbs.). 4. Push the arm cap cover
down. 5. Engage clip to the hold outside end of wiper arm pivot cover to the wiper arm.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Arm > Component Information > Service and Repair >
Wiper Arm > Page 9034
Wiper Arm: Service and Repair Rear Wiper Arm
REMOVAL
1. Lift and hold wiper blade away from rear window. 2. Lift lock holding wiper arm to wiper pivot
upward. 3. Allow wiper arm to rest against lock.
Rear Wiper Arm
4. Pull wiper from pivot.
INSTALLATION
1. Push wiper from pivot. 2. Disallow wiper arm to rest against lock. 3. Lower lock holding wiper
arm to wiper pivot upward. 4. Lower and hold wiper blade away from rear window.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or Streak
Windshield
Wiper Blade: Customer Interest Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Blade: > 23-014-06 > Mar > 06 > Wipers/Washers - Wipers Smear or
Streak Windshield
Wiper Blade: All Technical Service Bulletins Wipers/Washers - Wipers Smear or Streak Windshield
NUMBER: 23-014-06
GROUP: Body
DATE: March 8, 2006
SUBJECT: Windshield Wiper Blade/Element Maintenance
MODELS: All
All All Chrysler Group Vehicles
DISCUSSION:
Windshield wiper blades/elements are frequently replaced unnecessarily. Because of the
environmental conditions vehicles can be operated in, a film can build up on both the windshield
and the windshield wiper elements that will cause poor cleaning/streaking of the windshield, and in
some instances, a chattering condition as the wipers blades travel across the windshield.
Replacement of the wiper blades/elements is normally NOT required to correct streaking issues. A
simple NORMAL MAINTENANCE cleaning of the wiper blades/elements and windshield is all that
is required.
If the wipe pattern appears to be streaky or if there is chatter and no damage to the wiper
blades/elements is obvious, the following steps should be performed:
1. Use a soft cloth or sponge & squeegee and MOPAR Windshield Washer Solvent (p/n
04318067AB, 16 Oz. bottle or p/n 04318068AB, 32 Oz. bottle), MOPAR Glass Cleaner (p/n
04897623AB, 16 Oz. bottle) or a solution of 50/50 alcohol and water, to wash the windshield.
2. Raise the wiper blades off the glass and clean the wiper blade elements (rubber insert) with
MOPAR Windshield Washer Solvent or a solution of 50/50 alcohol and water and a soft cloth,
paper towel or sponge.
3. Return the wiper blades to their normal operating position and function the washer system. If the
wiper blades/elements are not streaking the windshield or chattering, replacing the blade
assembly(ies) is not necessary. If the wipe pattern is still objectionable, repeat step 2 several times.
If the wipe pattern is still objectionable, replace the wiper blades/elements.
POLICY: Information Only
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Technical Service
Bulletins > Page 9048
Wiper Blade: Testing and Inspection
Cleaning and Inspection Wiper blades exposed to the weather for a long period of time tend to lose
their wiping effectiveness.
Periodic cleaning of the wiper blade is recommended to remove the accumulation of salt and road
grime.
The wiper blades, arms and windshield should be cleaned with a sponge or cloth and a mild
detergent or nonabrasive cleaner.
If the wiper blades continue to streak or smear, they should be replaced.
The wiper blade should run smoothly across the windshield in both directions. The wiper blade
should slightly roll over center when the blade reverses direction.
A wiper blade insert that has lost flexibility or a wiper arm that has lost spring tension, will cause the
blade to skip or chatter across the windshield. If the wiper blades are new and the wiper arm spring
tension is OK and a chattering sound is emitted from the wiper(s), the wiper blade is not rolling over
center. If this condition exists, refer to the Wiper Arm Alignment.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Rear Wiper Blade
Wiper Blade: Service and Repair Rear Wiper Blade
REMOVAL
Rear Wiper Arm
1. Lift wiper blade away from rear window. 2. Release latch holding blade to wiper arm. 3. Remove
blade from wiper arm.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Rear Wiper Blade > Page 9051
Wiper Blade: Service and Repair Wiper Blade
REMOVAL
1. Lift the wiper arm away from windshield.
Windshield Wiper Blade
2. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade
from the wiper arm. 3. Remove the wiper blade from the wiper arm.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Rear Wiper Blade > Page 9052
Wiper Blade: Service and Repair Wiper Blade Element
REMOVAL
Windshield Wiper Blade
1. Disengage the release tab holding the wiper blade to the wiper arm and remove the wiper blade
from the wiper arm.
Windshield Wiper Blade Element
2. Disengage clip holding the wiper element to wiper blade. 3. Pull the element from the claws on
the wiper blade.
INSTALLATION
Wiper Blade And Element
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Blade > Component Information > Service and Repair >
Rear Wiper Blade > Page 9053
1. Insert the element vertebra into claw at the open end of the wiper blade and through each claw
location along the blade. 2. Engage clip to hold wiper element to wiper blade. 3. Test wiper
effectiveness using washer mode and align if necessary.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
> Page 9062
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
> Page 9063
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
> Page 9064
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > Customer Interest for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks Onto The Floor
> Page 9065
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor
Technical Service Bulletin # 23-43-97A Date: 970912
Evaporator Housing - Water Leaks Onto The Floor
NO: 23-43-97 Rev. A
GROUP: Body
DATE: Sep. 12, 1997
SUBJECT: Water Leaks Onto The Passenger Side Floor From The HVAC Housing
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 23-43-97, DATED AUG. 1,
1997, WHICH SHOULD BE REMOVED FROM YOUR FILES. THE REVISION ELIMINATES
DRILLING A HOLE AND INSTALLING A SCREW IN THE REAR PLENUM WALL. **
ASTERISKS** ARE USED TO HIGHLIGHT THE CHANGES.
MODELS:
1996 - 1998 (NS) Town & Country/Caravan/Voyager
1996 - 1998 (GS) Chrysler Voyager (International Market)
NOTE:
THIS BULLETIN APPLIES TO LEFT HAND DRIVE (LHD) VEHICLES.
SYMPTOM/CONDITION:
Several conditions can cause water to leak onto the carpet from the HVAC housing. These may
include, hood mis-alignment, cowl cover mis-alignment, wiper module drain tube(s), and/or the
lower plenum drain hose.
DIAGNOSIS:
Inspect the fit between the hood and the cowl cover and the hood and front fenders. The gaps
should be 5 mm - 3 mm (3/16 - 1/8 in.) and the hood should be flush to 1.5 mm (1/16 in.) under
flush.
Inspect the cowl cover to windshield, the weatherstrip MUST be in full contact all the way across
the windshield and stuck to the cowl cover.
Inspect the cowl cover to hood, the weatherstrip MUST be in full contact all the way across the
hood and stuck to the cowl cover.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 9071
Inspect the wiper module drain tubes (2), and the lower plenum drain hose to ensure they are fully
seated and not restricted, kinked or plugged, see Figure 1.
PARTS REQUIRED:
AR (1) 05010842AA Deflector
AR (2) 0153185 Screw
AR (1) 04885330AA Super Kleen
AR (1) 04318025 Sealant, Silicone
REPAIR PROCEDURE:
This bulletin involves adjusting the hood and/or cowl cover and/or removing any restriction from the
wiper module drain tubes (2) and/or lower plenum drain hose and possibly installing a deflector in
the cowl plenum.
POLICY: Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Labor Operation No:
23-50-02-93 Procedure A 0.5 Hrs.
23-50-02-94 Procedure B 1.2 Hrs.
FAILURE CODE: XX - Service Adjustment
Procedure A
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 9072
1. Position the cowl cover so its weather strip contacts the windshield all the way across. If the cowl
cover is not attached with screws and the cowl cover can't be adjusted so its weather strip contacts
the windshield all the way across, refer to Technical Service Bulletin 23-61-95, dated 10/27/95.
2. Adjust the hood to get 5 mm - 3 mm (3/16 - 1/8 in.) gaps between the front fenders to hood and
hood to cowl cover. Loosening the hood to hood hinge bolts will allow the hood to be repositioned
to achieve the required gaps. The correct torque for the hood to hood hinge bolts is 11.3 - 15.8 Nm
(100 - 140 in. lbs.).
3. Adjust the hood so that it is flush to 1.5 mm (1/16 in.) under flush to the fender and cowl cover.
Loosening the hood hinge to fender bolts will allow the hood to be repositioned to achieve the
required flushness and ensure the cowl cover weatherstrip contacts the hood all the way across.
The correct torque for the hood hinge to fender bolts is 9.6 - 13.6 Nm (85 - 125 in. lbs.).
4. Remove any restriction(s) effecting the ability of the wiper module drain tubes to flow water, i.e.
kinks, tie straps too tight, foreign material in tubes, etc.
5. Ensure the wiper module drain tubes (2) are fully seated on the module spouts.
6. Remove any restriction(s) effecting the ability of the lower plenum drain hose flow water.
7. Ensure the lower plenum drain hose and grommet are seated.
8. With the engine running and HVAC blower set to the High speed position, spray water at less
than 10 psi on the base of the windshield and cowl cover area at a rate that would be equivalent to
approximately 20 in. of water per hour for 10 minutes. If water leaks from the HVAC onto the
passenger side floor after ensuring proper hood/cowl cover fits and the drains are functioning
properly, perform Procedure B.
Procedure B
1. With the windshield wipers in the "Park" position, disengage the clip holding the outside end of
the wiper arm pivot cover to the wiper arm and lift the arm cap upward.
2. Remove the nut attaching the wiper arm to the wiper pivot.
3. Using a suitable 2 jaw puller, separate the wiper arm from the wiper pivot.
4. Repeat steps 1-3 for the other wiper arm.
5. Remove the screws attaching the lower area of the cowl cover to wiper module and disengage
the quarter turn fasteners holding the outer ends of the cowl cover to the wiper module.
6. Open the hood and remove the wing nuts attaching the front of the cowl cover to the wiper
module.
7. Lower the hood and remove the cowl cover outboard attaching screws.
8. Raise the right side of cowl cover and disconnect the washer hose from the right side washer
nozzle.
9. Separate the cowl cover from the vehicle.
10. Open the hood.
11. Disengage the positive lock on the wiper module wiring connector and disconnect the engine
wiring harness from the wiper module connector.
12. Disconnect the washer hose from the wiper module.
13. Disconnect the two drain tubes from the bottom of the wiper module.
NOTE:
DO NOT ALLOW THE WIPER MODULE TO REST ON THE BRAKE MASTER CYLINDER,
DAMAGE TO THE BRAKE SYSTEM MAY RESULT.
14. Remove the nuts and bolts attaching the wiper module to the vehicle and separate the wiper
module from the vehicle.
15. Through the driver side plenum hole closest to the center of the vehicle locate the vertical tab
closest to the center of the vehicle and bend it flush with the plenum floor.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 9073
16. Insert the curved portion of deflector, p/n 05010842AA into the passenger side plenum hole
closest the center of the vehicle toward the driver side of the vehicle until the entire deflector is
inside the plenum, Figure 2.
17. Slide the deflector toward the passenger side of the vehicle and position it in front of and
around the holes in the plenum floor.
18. Pull the outboard side of the deflector forward against the front plenum wall and attach a
"C"-clamp or vise grip plier to hold the deflector in position, Figure 3.
**19. Push the inboard end of the deflector rearward against the rear plenum wall. Use the hole in
bottom flange of the deflector (Location 2 in Figure 3)
as a guide to drill a 7/64 in. pilot hole in the plenum floor.**
20. Drill a 7/64 in. pilot hole through the front plenum wall and the vertical flange of the deflector
(Location 3, Figure 3).
21. Remove the holding device used in step 18 and remove all metal particles created by drilling
the three pilot holes.
22. Note the "foot print" of the deflector on the plenum floor and vertical walls, then move the
deflector toward the center of the vehicle away from the holes in the passenger side of the plenum
floor. Use Mopar Super Kleen, p/n 04885330AA, to clean the "foot print" area on the plenum floor
and vertical walls. Apply a generous bead of silicone sealer, p/n 04318025, to the deflector "foot
print" area of the plenum.
23. Reposition the deflector over the holes in the passenger side of the plenum. Coat the threads of
2 screws, p/n 0153185, with silicone sealer and use them to attach the deflector to the plenum.
NOTE:
PROPER APPLICATION OF SILICONE SEALER IS CRITICAL FOR THIS REPAIR TO BE
EFFECTIVE.
24. Apply silicone sealer to the edges of the deflector to completely seal it to the plenum floor, the
inboard vertical flange and the outboard vertical flange to the plenum walls. Smooth the sealer flat
and keep the drain hole in the rear of the plenum floor near the inboard vertical flange of the
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Technical Service
Bulletins > All Technical Service Bulletins for Wiper Motor: > 23-43-97A > Sep > 97 > Evaporator Housing - Water Leaks
Onto The Floor > Page 9074
deflector free of sealer.
25. Install the wiper module and cowl cover by reversing the removal procedure.
26. Ensure the cowl cover fit provides full weatherstrip seal contact at the rear of the hood and the
base of the windshield and the drain tubes are connected to the wiper module.
27. Install the wiper arms so they are aligned as shown in Figure 4. Torque the attaching nuts to 35
Nm (26 ft. lbs.)
28. Allow the silicone sealer to cure 3 hrs. before exposing to the vehicle to temperatures below
65°F. (18°C.)
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement
Wiper Motor: Service and Repair Rear Wiper Motor Replacement
REMOVAL
1. Remove rear wiper arm. 2. Open liftgate. 3. Remove liftgate trim panel. 4. Disconnect wire
connector from rear wiper motor.
Rear Window Wiper Motor
5. Remove screws holding rear wiper motor to liftgate. 6. Remove wiper motor from liftgate.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor > Component Information > Service and Repair >
Rear Wiper Motor Replacement > Page 9077
Wiper Motor: Service and Repair Replacement
REMOVAL
1. Remove the wiper arms. 2. Remove the cowl cover.
Wiper Unit Wire Connector
3. Release the hood latch and open hood. 4. Disconnect the positive lock on the wiper unit wire
connector. 5. Disconnect the wiper unit wire connector from the engine compartment wire harness.
6. Disconnect the windshield washer hose from coupling inside unit. 7. Disconnect the drain tubes
from nipples on bottom of the wiper unit. 8. Remove nuts holding wiper unit to lower windshield
fence.
Wiper Unit
9. Remove bolts holding the wiper unit to the dash panel.
10. Lift wiper unit from weld-studs on lower windshield fence.
CAUTION: Do not allow wiper unit to rest on brake master cylinder reservoir, damage to brake
system can result.
11. Remove wiper unit.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Motor Linkage > Component Information > Service and
Repair
Wiper Motor Linkage: Service and Repair
REMOVAL
1. Remove the windshield wiper unit from vehicle. 2. Place the wiper unit on a suitable work
surface. 3. Remove nuts holding the cowl cover brackets to the wiper unit. 4. Remove cowl cover
brackets from the wiper unit. 5. Remove nuts holding linkage and motor mount plate to the wiper
unit.
Wiper Linkage
6. Remove the wiper linkage from the wiper unit.
Wiper Motor Connector
7. Disconnect the wire connectors from back of the wiper motor.
INSTALLATION
- For Installation, reverse the above procedures.
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Relay > Component Information > Locations
Power Distribution
Dodge Grand Caravan Fwd Workshop Manual (V6-201 3.3L VIN R MFI (1998))
Dodge Workshop Manuals > Wiper and Washer Systems > Wiper Switch > Component Information > Testing and
Inspection
Wiper Switch: Testing and Inspection
To test the windshield wiper and washer portion of the multi-function switch:
1. Remove the multi-function switch.
Windshield Wiper And Washer - Multi Function Switch Test
2. Using an ohmmeter check continuity reading between switch pins, refer to proper pin numbers.
Switch Position = Resistance Value Between
OFF = 6 AND 7 - MAX 1.0 Ohms
Delay Position
1ST = 6 AND 7 - 1.91 K Ohms +/- 5 Ohms 2ND = 6 AND 7 - 1.00 K Ohms +/- 5 Ohms 3RD = 6
AND 7 - 617 - Ohms +/- 5 Ohms 4TH = 6 AND 7 - 389 Ohms +/- 2 Ohms 5TH = 6 AND 7 - 256
Ohms +/- 2 Ohms 6TH = 6 AND 7 - 156 Ohms +/- 2 Ohms LOW = 6 AND 7 - 65.4 Ohms +/- 0.5
Ohms HIGH = 5 AND 8 - MAX 1.0 Ohms WASH = 8 AND 11 - CONTINUITY